Patent Application
20140373935
The present invention relates to an improvement in a gas supplying apparatus for semiconductor manufacturing equipment, and specifically, to a gas branched flow supplying apparatus for semiconductor manufacturing equipment that includes a plurality of high-speed opening/closing valves joined in parallel on the downstream side of a pressure type flow control system, and by controlling the opening and closing order and the opening and closing times of the respective high-speed opening/closing valves, accurately branches and supplies required amounts of a process gas to a plurality of process chambers that perform the same process, and by organically combining a thermal type flow control system with the pressure type flow control system, it is enabled to arbitrarily check an actual flow rate of the process gas during branched flow supply.
In the gas supplying apparatus for a semiconductor control device, conventionally, a thermal type flow control system and a pressure type flow control system FCS are widely used.
In this pressure type flow control system, detection values from the pressure detector P and the temperature detector T are converted into digital signals and input into the temperature correction/flow rate arithmetic circuit CDa, and here, temperature correction of the detected pressure and flow rate computation are performed, and then, a computed flow rate value Qt is input into the comparison circuit CDb. On the other hand, a set flow rate input signal Qs is input from the terminal In, converted into a digital value in the input-output circuit CDc, and then input into the comparison circuit CDb, and here, compared with the computed flow rate value Qt from the temperature correction/flow rate arithmetic circuit CDa. When a set flow rate input signal Qs is larger than the computed flow rate value Qt, a control signal Pd is output to the drive unit of the control valve CV, and the control valve CV is driven in an opening direction via a drive mechanism CVa thereof. That is, the control valve is driven in the valve opening direction until the difference (Qs−Qt) between the set flow rate input signal Qs and the arithmetic flow rate value Qt becomes zero.
The pressure type flow control system FCS itself is known, and has excellent characteristics in which, between the downstream side pressure P2 of the orifice OL (that is, the pressure P2 on the process chamber side) and the upstream side pressure P1 of the orifice OL (that is, the pressure P1 on the outlet side of the control valve CV), when the relationship of P1/P2≧approximately 2 (hereinafter, the so-called critical expansion condition) is held, the flow rate Q of the gas Go distributed through the orifice OL satisfies Q=KP1 (herein, K is a constant), and by controlling the pressure P1, the flow rate Q can be controlled with high accuracy, and even if the pressure of the gas G0 on the upstream side of the control valve CV greatly changes, the controlled flow rate value hardly changes.
Thus, in the gas supply equipment for semiconductor manufacturing equipment of a type that branches and supplies a gas to one or a plurality of process chambers, as shown in
Therefore, the pressure type flow control system must be installed for each branched flow passage of the process gas, so that there is a basic problem in which downsizing and reductions in the cost of the gas supplying apparatus for semiconductor manufacturing equipment are difficult.
In
To solve the problem described above in the gas supplying apparatus shown in
However, in the flow control system (branched flow supplying apparatus) disclosed in Japanese Published Unexamined Patent Application No. 2003-323217 described above, the automatic pressure controller ACP, the control unit ACQ, and the orifices SN1 and SN2 are installed individually, and the primary side pressure P1 is set to three times as high as the secondary side pressure P2 to make the flow rates Q1 and Q2 proportional to the primary side pressure P1, and the gas flows that are distributed through the orifices SN1 and SN2 are made as flows in the critical states.
As a result, it is necessary to appropriately assemble and integrate the automatic pressure controller ACP, the control unit ACQ, and the orifices SN1 and SN2, etc., so that manufacturing of the gas supplying apparatus becomes troublesome, and in addition, it is difficult to downsize and compactify the gas supplying apparatus.
In addition, the control system of the control unit ACQ and the automatic pressure controller ACP does not adopt so-called feedback control, and as a result, it becomes difficult for the automatic pressure controller ACP to swiftly adjust the fluctuation of the primary side pressure P1 caused by opening and closing operations of the opening/closing valves V1 and V2, and the flow rate Q1 (or flow rate Q2) easily fluctuates.
Further, the primary side pressure P1 is regulated by the automatic pressure controller ACP, and in a state where the ratio P1/P2 of the primary side pressure P1 to the secondary side pressure P2 of the orifice is held at approximately 3 or more, the branched flow rates Q1 and Q2 are controlled, so that when the value of P1/P2 approaches approximately 2 and the gas flow becomes a gas flow under a so-called non-critical expansion condition, accurate branched flow control becomes difficult.
In addition, for switching control of the respective branched flow passages for supplying the flow rates Q1 and Q2, opening/closing valves V1 and V2 are always necessary in addition to the orifices SN1 and SN2, so that it is difficult to realize downsizing and compactification and a significant reduction in manufacturing cost of the gas supplying equipment.
Patent Document 1: Japanese Published Unexamined Patent Application No. 2008-009554
Patent Document 2: Japanese Published Unexamined Patent Application No. 2000-305630
Patent Document 3: Japanese Published Unexamined Patent Application No. 2003-323217
Various embodiments of the present invention solve the above-described problems in a gas branched flow supplying apparatus using a conventional pressure type flow control system, that is, (a) downsizing and reductions in the cost of the gas supplying apparatus are difficult when the pressure type flow control system is provided for each gas supply line (each branched flow line), (b) when the primary side pressure P1 of each orifice is regulated by an automatic pressure controller provided on the gas supply source side, and the respective branched gas flow rates Q1 and Q2 in proportion to the pressure P1 are supplied through the respective orifices, assembling and manufacturing of the gas supplying apparatus are troublesome and downsizing and compactification of the apparatus are difficult, when any of the branched flow passages is opened or closed, the orifice primary side pressure P1 fluctuates and the branched flow rate of the other branched flow passage (or passages) easily fluctuates, and it becomes difficult to control the branched flow rates Q1 and Q2 with high accuracy when the ratio P1/P2 of the orifice primary side pressure P1 to the secondary side pressure P2 becomes a value (for example, approximately 2 or less in the case of O2 or N2) out of the critical expansion condition, etc., and by using a gas branched flow supplying apparatus structurally simplified and downsized, the present invention provides a gas branched flow supplying apparatus for semiconductor manufacturing equipment which can divide and supply a process gas to a number of process chambers performing the same process economically while performing highly accurate flow control, and by organically integrating a pressure type flow control system and a thermal type flow control system, can perform highly accurate branched flow supply even in a state out of the critical expansion condition, and arbitrarily perform actual flow rate monitoring of the process gas being supplied as necessary.
As a means for solving the problems, first, the inventors of the present application conceived of a system that supplies the same amounts of gas to the respective branched flow passages per unit time by controlling the supply flow rate from the gas supply source by the pressure type flow control system and supplying the gas at the controlled flow rate to the plurality of branched flow passages while switching the branched flow passages at each short amount of time. That is, a pressure type flow control system is constructed in which the respective orifices SN1 and SN2 in the gas supply system described in
Simultaneously with this, the inventors repeatedly investigated the relationship between actual supply modes of the process gas to process chambers for semiconductor manufacturing equipment and the results of process treatment, etc.
As a result, it was found that the supply of the process gas to the process chambers does not have to be always at a constant uniform flow rate, and keeping of the total supply amount of the process gas in a predetermined time at a set value is the most important element in process treatment.
That is, even a gas supply mode in which the process gas is intermittently supplied to the respective branched flow passages by automatically switching the opening/closing valves V1 and V2 described above alternately at each short amount of time can be sufficiently put into practical use as long as the total gas supply amount to be supplied to the respective branched flow passages in a predetermined time can be controlled to a set value with high accuracy.
The present invention was made based on the above-described idea of the inventors and the results of various tests, and as a basic constitution of the invention according to a first aspect, a gas branched flow supplying apparatus for semiconductor manufacturing equipment includes a control valve 3 forming a pressure type flow control unit 1a connected to a process gas inlet 11, a gas supply main pipe 8 communicatively connected to the downstream side of the control valve 3, an orifice 6 provided in the gas supply main pipe 8 on the downstream side of the control valve 3, a plurality of branched pipe passages 9a, 9n connected in parallel on the downstream side of the gas supply main pipe 8, branched pipe passage opening/closing valves 10a, 10n interposed in the respective branched pipe passages 9a, 9n, a pressure sensor 5 provided in the process gas passage between the control valve 3 and the orifice 6, branched gas flow outlets 11a, 11n provided on the outlet sides of the respective branched pipe passages 9a, 9n, and an arithmetic and control unit 7 into which a pressure signal from the pressure sensor 5 is input, and which computes a total flow rate Q of the process gas distributed through the orifice 6 and outputs a control signal Pd to a valve drive unit 3a to operate the control valve 3 to open and close in a direction in which the difference between the computed flow rate value and a set flow rate value decreases, and outputs opening-closing control signals Oda, Odn to the branched pipe passage opening/closing valves 10a, 10n to successively open the respective branched pipe passage opening/closing valves 10a, 10n for a predetermined time and then close the valves, and the gas branched flow supplying apparatus performs flow control of the process gas distributed through the orifice 6 by the pressure type flow control unit 1a, and branches and supplies the process gas by opening and closing the branched pipe passage opening/closing valves 10a, 10n.
As a basic constitution of the invention according to a second aspect, a gas branched flow supplying apparatus for semiconductor manufacturing equipment includes a control valve 3 constituting a pressure type flow control unit 1a connected to a process gas inlet 11, a thermal type flow sensor 2 constituting a thermal type flow control unit 1b connected to the downstream side of the control valve 3, a gas supply main pipe 8 communicatively connected to the downstream side of the thermal type flow sensor 2, a plurality of branched pipe passages 9a, 9n connected in parallel on the downstream side of the gas supply main pipe 8, branched pipe passage opening/closing valves 10a, 10b interposed in the respective branched pipe passages 9a and 9n, an orifice 6 provided in the gas supply main pipe 8 on the downstream side of the control valve 3, a temperature sensor 4 provided near a process gas passage between the control valve 3 and the orifice 6, a pressure sensor 5 provided in the process gas passage between the control valve 3 and the orifice 6, branched gas flow outlets 11a, 11n provided on the outlet sides of the branched pipe passages 9a, 9n, and an arithmetic and control unit 7 including a pressure type flow rate arithmetic and control unit 7a into which a pressure signal from the pressure sensor 5 and a temperature signal from the temperature sensor 4 are input, and which computes a total flow rate Q of the process gas distributed through the orifice 6 and outputs a control signal Pd to a valve drive unit 3a to operate the control valve 3 to open and close in a direction in which the difference between the computed flow rate value and a set flow rate value decreases, and outputs opening-closing control signals Oda, Odn to the branched pipe passage opening/closing valves 10a, 10n to successively open the respective branched pipe passage opening/closing valves 10a, 10n for a predetermined time and then close the valves, and a thermal type flow rate arithmetic and control unit 7b into which a flow rate signal 2c from the thermal type flow sensor 2 is input, and which computes and displays a total flow rate Q of the process gas distributed through the gas supply main pipe 8 from the flow rate signal 2c, and the gas branched flow supplying apparatus performs process gas flow control by the pressure type flow control unit 1a when the process gas flow distributed through the orifice 6 is a gas flow satisfying the critical expansion condition and performs process gas flow control by the thermal type flow control unit 1b when the process gas flow is a gas flow not satisfying the critical expansion condition, and branches and supplies the process gas by opening and closing the branched pipe passage opening/closing valves 10a, 10n.
The invention according to a third aspect is the invention according to the first or second aspect, characterized in that the opening times of the plurality of branched pipe passage opening/closing valves 10a, 10n are set equal to each other, and process gas Qa, Qn at the same flow rate are supplied to the respective branched pipe passages 9a, 9n.
The invention according to a fourth aspect is the invention according to the first or second aspect which is characterized in that a process gas is distributed through only an arbitrary branched pipe passage (or passages) of the plurality of branched pipe passages 9a, 9n.
The invention according to a fifth aspect is the invention according to the first aspect, characterized in that the control valve 3, the orifice 6, the pressure sensor 5, the temperature sensor 4, the branched pipe passages 9a, 9n, the branched pipe passage opening/closing valves 10a, 10n, and the gas supply main pipe 8 are integrally formed and assembled in one body.
The invention according to a sixth aspect is the invention according to the second aspect, characterized in that the control valve 3, the thermal type flow sensor 2, the orifice 6, the pressure sensor 5, the temperature sensor 4, the gas supply main pipe 8, the branched pipe passages 9a, 9n, and the branched pipe passage opening/closing valves 10a, 10n are integrally formed and assembled in one body.
The invention according to a seventh aspect is the invention according to the second aspect, characterized in that the flow rate of the process gas is controlled by the pressure type flow control unit 1a, and the actual flow rate of the process gas is displayed by the thermal type flow control unit 1b.
The invention according to an eighth aspect is the invention according to the second aspect, characterized in that the pressure sensor 5 is provided between the outlet side of the control valve 3 and the inlet side of the thermal type flow sensor 2.
The invention according to a ninth aspect is the invention according to the second aspect, characterized in that when the difference between a fluid flow rate computed by the pressure type flow rate arithmetic and control unit 7a and a fluid flow rate computed by the thermal type flow rate arithmetic and control unit 7b exceeds a set value, the arithmetic and control unit 7 displays a warning.
According to the present invention, by one pressure type flow control unit, or by one pressure type flow control unit and one thermal type flow control unit, a process gas is supplied to a plurality of process chambers through the plurality of branched pipe passage opening/closing valves 10a, 10n connected in parallel, so that the gas branched flow supplying apparatus can be significantly simplified and compactified in structure. When the plurality of branched pipe passage opening/closing valves 10a, 10n are formed into the same branched pipe passage opening/closing valves and their opening times are set equal to each other, the process gas the flow rate thereof is controlled with high accuracy is branched and supplied at the same flow rate simultaneously to the plurality of process chambers that perform the same process, and the gas branched flow supplying apparatus can be further downsized.
The respective members constituting the gas branched flow supplying apparatus are integrally assembled in one body, so that the gas branched flow supplying apparatus can be significantly downsized.
Further, automatic opening/closing control of the respective branched pipe passage opening/closing valves 10a, 10n is performed from the arithmetic and control unit, so that the process gas can be supplied only to an arbitrary branched pipe passage (or passages), and the branched pipe passage to which the gas is supplied can be easily switched one another.
In addition, a thermal type flow control unit is provided, so that the flow rate of even a process gas under the non-critical expansion condition can be controlled by the thermal type flow control unit with high accuracy, and even during flow control by the pressure type flow control unit under the critical expansion condition, checking, etc., of the actual flow rate can be arbitrarily performed by using the thermal type flow control unit.
Hereinafter, embodiments of the present invention are described based on the drawings.
Opening and closing of the branched pipe passage opening/closing valves 10a, . . . , 10n inside the respective branched pipe passages 9a, . . . , 9n joined in parallel are controlled by opening/closing control signals Oda, Odn from the pressure type flow control unit 1a, and as shown in the time chart TM in the drawing, the branched pipe passage opening/closing valves are successively opened for a predetermined time and then closed. That is, the respective branched pipe passage opening/closing valves 10a, 10n are not simultaneously opened, and only either one of the branched pipe passage opening/closing valves is always opened and the other branched pipe passage opening/closing valve (or valves) is held in a closed state. As a result, a process gas is branched and supplied at a flow rate corresponding to Q/n to the process chambers CHa, . . . , CHn connected to the respective branched pipe passages.
In
The respective branched pipe passage opening/closing valves 10a, 10n are normally-closed type electromagnetic opening/closing valves or piezoelectric element driving valves, and are opened by energization, and are closed by an elastic force of a spring in response to dissipation of a drive voltage.
In the case of the electromagnetic opening/closing valves, valves that can be switched from full closing to full opening at a high speed in at least 0.005 seconds or less when the gas pressure is 1 MPa and the diameter is 10 mm, and can be switched from full opening to full closing in 0.005 seconds or less, are preferably used.
In the present embodiment, as the electromagnetic opening/closing valves, solenoid opening/closing type electromagnetic valves made by Fujikin Incorporated and disclosed in International Publication No. WO 98/25062 are used, and as the piezoelectric element driving valves, piezoelectric element driving type electric control valves made by Fujikin Incorporated and disclosed in Japanese Published Unexamined Patent Application No. 2008-249002 are used. The electromagnetic opening/closing valves and piezoelectric element driving valves themselves are known, therefore, detailed descriptions thereof are omitted.
That is, the gas branched flow supplying apparatus 1 includes a thermal type flow sensor unit 2 forming the thermal type flow control unit 1b, a control valve 3 forming the pressure type flow control unit 1a, a temperature sensor 4, a pressure sensor 5, an orifice 6, an arithmetic and control unit 7 forming an arithmetic and control unit 7a of the pressure type flow control unit 1a and an arithmetic and control unit 7b of the thermal type flow control unit 1b, and a gas supply main pipe 8, etc., and when the gas distributed through the orifice 6 is under the critical expansion condition, for example, in a case where the gas is O2 or N2 gas and the upstream side pressure P1 and the downstream side pressure P2 of the orifice 6 satisfies the relationship of P1/P2>2, while flow control of a total flow rate Q is performed by the pressure type flow control unit 1a, the respective branched pipe passage opening/closing valves 10a, 10n are successively opened for a predetermined time and then closed by opening/closing control signals Oda, Odn from the pressure type flow control unit 1a as shown in the time chart TM of
The respective branched pipe passage opening/closing valves 10a, 10n do not open simultaneously, and only either one of the branched pipe passage opening/closing valves is always opened and the other branched pipe passage opening/closing valve (or valves) is held in a closed state. As a result, to the process chambers CHa, . . . , CHn connected to the branched pipe passages, respectively, process gas Qa, . . . , Qn at flow rates corresponding to Q/n are branched and supplied.
When the gas distributed through the orifice 6 is out of the critical expansion condition, while the process gas flow rate Qn is controlled by the thermal type flow control unit 1b, the respective branched pipe passage opening/closing valves 10a, . . . , 10n are successively opened for a predetermined time and then closed according to the time chart TM of
In
The pressure type flow control unit 1a includes a control valve 3, a temperature sensor 4, a pressure sensor 5, a plurality of orifices 6, and a pressure type flow rate arithmetic and control unit 7a forming an arithmetic and control unit 7.
The thermal type flow control unit 1b includes a thermal type flow sensor 2 and a thermal type flow rate arithmetic and control unit 7b forming the arithmetic and control unit 7.
The pressure type flow control unit 1a includes, as described above, the control valve 3, the temperature sensor 4, the pressure sensor 5, the orifice 6, and the pressure type flow rate arithmetic and control unit 7a, etc., and a flow rate setting signal is output from an input terminal 7a1, and a flow rate output signal of a total process gas flow rate distributed through the orifice 6 (that is, a process gas flow rate Q distributed through the gas supply main pipe 8) computed by the pressure type flow control unit 1a is output from the output terminal 7a2.
In the present example, the number of branched flow supply passages is two, so that two branched pipe passage opening/closing valves 10a, 10n are provided, however, normally, the number of branched flow supply passages (that is, the number of branched pipe passage opening/closing valves) is two or more.
Preferably, the diameters and opening times of the respective branched pipe passage opening/closing valves 10a, 10n, that is, the time chart TM of
The pressure type flow control unit 1a itself using the orifice 6 is a known technology as described in Japanese Patent No. 3291161, etc., and a flow rate of a fluid distributed through the orifice under the critical expansion condition is computed by the pressure type flow rate arithmetic and control unit 7a based on a pressure detected by the pressure detection sensor 5, and a control signal Pd in proportion to the difference between a set flow rate signal input from the input terminal 7a1 and the computed flow rate signal is output to a valve drive unit 3a of the control valve 3.
The constitutions of the pressure type flow control unit 1a and the flow rate arithmetic and control unit 7a thereof are known, therefore, detailed descriptions thereof are omitted here.
It is a matter of course that the pressure type flow control unit 1a is provided with various accessory mechanisms such as a known zero point adjustment mechanism, a flow rate abnormality detection mechanism, and a gas type conversion mechanism (CF value conversion mechanism).
Further, in
The thermal type flow control unit 1b constituting the gas branched flow supplying apparatus consists of the thermal type flow sensor 2 and the thermal type flow rate arithmetic and control unit 7b, and the thermal type flow rate arithmetic and control unit 7b is provided with an input terminal 7b1 and an output terminal 7b2. From the input terminal 7b1, a flow rate setting signal is input, and from the output terminal 7b2, a flow rate signal (actual flow rate signal) detected by the thermal type flow sensor 2 is output.
The thermal type flow control unit 1b itself is known, therefore, description thereof is omitted here. In the present example, as the thermal type flow control unit 1b, one installed in the FCS-T1000 series made by Fujikin Incorporated is used.
As a matter of course, between the thermal type flow rate arithmetic and control unit 7b and the pressure type flow rate arithmetic and control unit 7a, inputs and outputs of the actual flow rate signal and computed flow rate signal are appropriately performed, and whether the signals are different or equal is monitored or the amount of the difference between the signals is monitored, or a warning can be issued when the difference between the signals exceeds a predetermined value although these are not shown in
It is also possible that a pressure sensor is separately provided on the downstream side of the orifice 6 so that whether or not the fluid distributed through the orifice 6 is under the critical expansion condition is monitored and a warning is issued, and flow control is automatically switched from control by the pressure type flow control unit 1a to control by the thermal type flow control unit 1b although these are not shown in
Further, it is a matter of course that the branched pipe passage opening/closing valves 10a, 10n are appropriately driven to open and close by signals from the arithmetic and control unit 7.
In the embodiment shown in
In the embodiments and examples shown in
Further, in
Next, operation of the gas branched flow supplying apparatus according to the present invention is described. Referring to
Thereafter, by opening the opening/closing valve 15a on the process gas supply side and operating the pressure type flow rate arithmetic and control unit 7a, the control valve 3 is opened, and through the gas supply main pipe 8, the branched pipe passage opening/closing valves 10a, 10n, and the orifices 6a, 6n, branched gas, the total flow rate Q of which is Q=Qa+Qn corresponding to the set flow rate signal are supplied to each of the process chambers CHa, CHn from the branched gas flow outlets 11a, 11n.
The diameter of the orifice 6 is determined in advance based on the orifice primary side pressure P1 and the required flow rate Q=Qa, Qn, and by controlling the orifice primary side pressure P1 by adjustment of the opening degree of the control valve 3, the total flow rate Q=Qa+Qn is controlled to the set flow rate.
The gas branched flow supplying apparatus 1 according to the present invention is mainly used to supply a process gas to the process chambers CHa, CHn that perform the same process. Therefore, the diameters of the branched pipe passage opening/closing valves 10a, 10n are normally selected to be the same diameter. The valve opening times in the time chart TM of the branched pipe passage opening/closing valves 10a, 10n are appropriately set according to the branched flow supply amounts required for the process chambers CHa, CHn.
When the critical expansion condition is satisfied between the primary side pressure P1 and the secondary side pressure P2 of the orifice 6, flow control is performed by the pressure type flow control unit 1a. The thermal type flow control unit 1b is operated when necessary, and the actual flow rate of the process gas Q distributed inside the gas supply main pipe 8 is checked and displayed, etc.
On the other hand, according to the pressure conditions, etc., on the process chamber CHa, CHn side, when the process gas flow distributed through the orifice 6 is out of the critical expansion condition (P1/P2 2), the flow control by the pressure type flow control unit 1a is automatically switched to flow control by the thermal type flow control unit 1b, and by operating the thermal type flow rate arithmetic and control unit 7b instead of the pressure type flow rate arithmetic and control unit 7a, the process gas flow rate is controlled.
As a result, even in a case where the process gas flow distributed through the orifice 6 is out of the critical expansion condition, highly accurate flow control can be performed regardless of the pressure condition of P1/P2 described above.
In the respective examples described above, description is given on the assumption that the process gas flow is supplied to all of the plurality of branched pipe passages 9a, 9n, however, as a matter of course, the gas may be supplied only to a necessary branched pipe passage (or passages).
Further, in the respective examples described above, both of the pressure type flow control unit 1a and the thermal type flow control unit 1b are provided, however, it is certainly possible that the thermal type flow control unit 1b is omitted and the gas branched flow supplying apparatus is provided with only the pressure type flow control unit 1a, and in this case, the gas branched flow supplying apparatus can be further downsized and compactified.
The present invention can be widely applied not only to gas branched flow supplying equipment for semiconductor manufacturing equipment, but also to gas branched flow supplying equipment for chemical goods production equipment, etc.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2012-016266 | Jan 2012 | JP | national |
This is a National Phase Application in the United States of International Patent Application No. PCT/JP2012/006626 filed Oct. 17, 2012, which claims priority on Japanese Patent Application No. JP2012-016266, filed Jan. 30, 2012. The entire disclosures of the above patent applications are hereby incorporated by reference.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2012/006626 | 10/17/2012 | WO | 00 | 7/30/2014 |
