The present invention relates to a susceptor for epitaxial reactors and to a tool for the handling thereof.
As is known, epitaxial reactors are apparatus designed to treat substrates, often called “slices”, which are used by the microelectronics industry to produce electric components, in particular integrated circuits.
In order to perform this treatment it is required to heat the slices to a high temperature, usually higher than 1,000° C. When the treatment involves the epitaxial deposition of layers of silicon carbide—or “SiC” to use its chemical symbol—the temperature is very high, generally higher than 1,500° C.
The slices are placed on a tray—usually called a “susceptor”—inside a reaction chamber of the epitaxial reactor; the susceptor generally has recesses for housing the slices; there are susceptors provided with one recess only and susceptors provided with a plurality of recesses; there are susceptors with a substantially flat shape and susceptors with a truncated pyramid shape.
There are two categories of epitaxial reactors: those with cold walls and those with hot walls; when the treatment temperature is very high it is very preferable to use hot-wall reactors.
In epitaxial reactors, the heating may be provided by means of lamps via irradiation, resistors via conduction or inducers via electromagnetic induction; the susceptor has the function of supporting and often also the function of heating the substrates.
Usually, the susceptor remains inside the reaction chamber of the reactor and the slices are introduced into the chamber before treatment and are extracted from the chamber after treatment.
In some particular reactors, in particular those which operate at a very high temperature, in particular reactors for the epitaxial growth of layers of silicon carbide, the susceptor with the slices is introduced into the chamber before treatment and is extracted from the chamber after treatment.
In particular in the case of these particular reactors, it is important to have a method which is simple and reliable for introducing the susceptor into the chamber and for extracting the susceptor from the chamber.
The general object of the present invention is to satisfy this requirement.
This object is achieved by means of the susceptor and the tool having the characteristic features described in the accompanying claims.
The idea forming the basis of the present invention is to provide the susceptor with a projecting part able to be easily and reliably gripped by a tool.
According to a further aspect, the present invention also relates to an epitaxial reactor in which the susceptor may be introduced and extracted in an easy and reliable manner.
The present invention will emerge more clearly from the following description to be considered in conjunction with the accompanying drawings in which:
Both this description and these drawings are to be regarded solely as illustrative and therefore not limiting; moreover, it must be remembered that these figures are schematic and simplified.
In the chamber 1 of
The chamber 1 is particularly suitable for use in CVD (Chemical Vapour Deposition) reactors for the epitaxial growth of silicon carbide.
The chamber 1 has a cavity 12 able to house substrates on which layers of semiconductor material are deposited; for this purpose, the cavity 12 has a substantially flat bottom wall able to be arranged in a substantially horizontal position inside a CVD reactor; the cavity 12 is surrounded by other walls, in particular by an upper wall and by two side walls. The cavity 12 is able to be passed through longitudinally by reaction gases. The chamber 1 is able to be heated in such a way as to heat the walls of the cavity 12 and therefore also the reaction gases which flow inside it. The chamber 1 is able to be heated by means of electromagnetic induction; for this purpose, the chamber 1 is typically made of graphite and coated with a protective layer of silicon carbide or tantalum carbide. The chamber 1 shown in
Chambers similar to that in
In reaction chambers of the type shown in
In the reaction chambers of the same type as that shown in
In chambers such as that shown in
In the example of
The substrate support of a chamber such as that shown in
The chamber 1 in
Many functional and constructional details relating to a chamber such as that shown in
The reaction chamber of an epitaxial reactor must be physically isolated from the environment which surrounds it in order to control accurately the reaction environment. The reaction chamber of an epitaxial reactor must also be thermally isolated from the environment which surrounds it; in fact, during the epitaxial growth processes, the chamber and its environment are subject to a temperature of between 1000° C. and 2000° C. (depending on the material to be deposited) and it is therefore important to limit the loss of heat; for this purpose, the chamber is surrounded by a thermal insulation structure.
In the example shown in
These openings are also used for loading and unloading the substrates, or rather in order to introduce and extract the susceptor 3 with the substrates, using suitable tools, in particular using the tool according to the present invention. It is preferable to use only one of the two openings both for loading and for unloading, in particular the opening 221B for exit of the exhaust gases.
The assembly according to
An inlet union 6 and an outlet guide 7 are envisaged; these parts are typically made of quartz; the inlet union 6 has the function of joining together a reaction gas supply duct (not shown in
A solenoid 5 which generates an electromagnetic field able to heat the chamber 1 by means of electromagnetic induction is wound around the tube 4, in the central zone, near the assembly of
Two lateral flanges, on the left-hand side 8A and right-hand side 8b, which are typically made of metal and are used to fix the tube to the body of the epitaxial reactor, are provided at the two ends of the tube 4.
As already mentioned, the assembly according to
The susceptor 3 according to
The tool 9 is specifically designed to grip the part 32 of the susceptor 3. It consists of a bar 91 which, at one of its ends (right-hand end in
The tool 9 according to
In general, the support for substrates according to the present invention comprises a projecting part designed to be gripped by a tool so as to be introduced into and extracted from a reaction chamber of an epitaxial reactor. Obviously, it is possible to envisage more than one projecting part, even though this complicates the structure of the substrate support.
In particular, the substrate support according to the present invention is a susceptor and may be used advantageously in an epitaxial reactor; typically the susceptor comprises a body having at least one recess for housing a substrate on which epitaxial growth is to be performed.
According to its simplest embodiment, the projecting part is a pin.
In order to grip the susceptor easily, it is possible to shape suitably its projecting part. According to one advantageous possibility, the projecting part is a pin which comprises a shank and a head; a first end of the shank is joined to the body and a second end of the shank is joined to the head.
In this case, for the sake of simplicity, both the shank and the head may have the shape substantially of a cylinder and may be substantially coaxial; preferably the diameter of the head is two or three times the diameter of the shank; preferably the height of the shank is two or three times the height of the head. In the example according to
The present invention is applied typically to susceptors having a body which is substantially disc-shaped.
In such a case, it is advantageous to position the projecting part substantially in the centre of the disc; in this way, when the projecting part is gripped by the tool, the susceptor is in equilibrium.
According to the preferred embodiment of the susceptor according to the present invention, all the recesses for the susceptor substrate are positioned on one side of the disc of the susceptor and the projecting part is positioned in the centre on the same side of the disc; in this way, when the projecting part is gripped by the tool, not only is the susceptor in equilibrium, but it also automatically remains in equilibrium.
There are two ways of designing the susceptor with the projecting part according to the present invention.
According to a first constructional possibility, the projecting part is formed as one piece with the body of the susceptor.
According to a second constructional possibility, the projecting part is mounted on the susceptor body, for example by means of screwing or gluing.
As regards the materials to be used for the susceptor according to the present invention, these depend on various factors.
The most typical application of the present invention is in epitaxial reactors with induction heating.
In this case, the body of the susceptor is preferably made of electrically conductive material, preferably graphite; moreover, it is preferable that the projecting part should also be made of electrically conductive material, preferably the same material as the body of the susceptor, preferably graphite.
In many cases, in particular for the epitaxial deposition of silicon or silicon carbide, it is advantageous to coat both the body and the projecting part with a layer of inert and refractory material, preferably silicon carbide (chemical symbol SiC) or tantalum carbide (chemical symbol TaC).
In the case where the projecting part is mounted on the body of the susceptor, it is advantageous for the layers coating the body and the projecting part to be formed after application of the projecting part to the body; in this way, the susceptor consists of two parts, but it may have characteristics similar to those of a susceptor constructed as one piece.
As can be seen from the paragraphs above, the susceptor according to the present invention will frequently be made of graphite. In this case, producing the susceptor as one piece is very costly (because it must be obtained by shaping a large piece of graphite), but provides advantages both because it is more solid and because it is thus more resistant to the physical and chemical agents which are very aggressive inside the reaction chamber of an epitaxial reactor.
It is worth pointing out that, in the case where the susceptor is coated with layer of material, it is preferable for it not to have sharp corners and for the joining radii to be carefully designed so as to be obtained a uniform thickness of the coating layer and limit the thermal and mechanical stresses; moreover, it is important to achieve good adhesion of the coating layer to the underlying material; in the case of graphite coated with tantalum carbide, the problem of adhesion is particularly relevant. In the example of embodiment shown in
Generally, the tool according to the present invention is specifically designed to grip a projecting part of a susceptor according to the present invention.
This tool may be used manually.
Alternatively, this tool may comprise means for mounting or engagement thereof on the arm of a robot and therefore may be used in an automatic or semi-automatic system for handling susceptors. The tool according to
According to a very simple, but very effective example of embodiment, the tool according to the present invention comprises a bar which, at one of its ends, has a slot. Obviously the slot has the function of cooperating with a corresponding part of the susceptor, for example engaging with the shank of the pin underneath the head of the pin as in the case of
In the example according to
The bar according to
Preferably, at the end where the slot is situated, the bar has a substantially rectangular cross-section; in this case, suitable dimensions of the bar may envisage a width of the bar 3 to 9 times the thickness of the bar and suitable dimensions of the slot may envisage a width of the slot 1 to 3 times the thickness of the bar; the thickness of the bar will typically range between 5 mm and 15 mm depending on its material and the weight of the susceptor which must be handled.
In order to obtain a smaller size engaging area, it is possible to envisage providing the bar with at least one recess along the slot; this recess may be used advantageously to house partially or entirely the head of the pin of the susceptor; this recess may also have the function of ensuring a more reliable engagement. The recess may extend over the entire length of the slot, as in the example of
The bar may have advantageously more than one recess for the head of the susceptor pin.
There may be two recesses, for example cylindrical recesses with slightly different diameters, in two positions preferably close to the slot; if the recess has the form of a truncated cone, the susceptor tends to be centred automatically with respect to the recess and therefore with respect to the bar (in the case of slight misalignment) since the head may slide along the side wall of the cone. The two different recesses are useful, for example, since during the growth processes, layers of material are deposited on the head of the pin and increase the dimensions thereof; in this way, the small recess is used when the head is small and the large recess is used when the head is large.
Moreover, it is possible to envisage a first recess which extends over the whole length of the slot and a second recess, which is for example cylindrical or frusto-conical, in an end position or middle position of the slot; the first recess may advantageously be provided with a receiving surface, for example with a conical shape, so that the head of the susceptor pin is able to slide and engage inside the second recess.
The tool according to
It may be useful to envisage that the slot of the bar has a receiving surface at its front end, namely at its inlet; in this way, for example, it will be easier to insert the shank of the susceptor pin into the slot and moreover it will be possible to compensate for slight misalignment between the slot and shank.
As an alternative to or in addition to the receiving surface at the inlet of the slot, it is possible to envisage that the width of the slot is quite larger than the diameter of the shank so as to compensate for slight misalignment between slot and shank and avoid (or at least limit) contact between tool and shank of the susceptor.
The tool according to the example in
The tool could envisage an articulation having preferably the possibility of limited rotation, preferably less than 10°; in the case of the bar, the articulation could be positioned in a middle position thereof, for example close to the end where the susceptor is gripped; in this way it will be easier to grip the susceptor, in particular insert the shank of the pin into the slot and compensate for slight misalignment between tool and susceptor. The articulation may advantageously be combined with the receiving surface at the inlet of the slot.
As mentioned, the tool according to the present invention has the function of gripping a susceptor, designed typically for epitaxial reactors, in order to introduce it into and extract it from the reaction chamber.
Generally, the tool extracts the susceptor with the substrates grown at a temperature ranging from 200° C. to 400° C. and the slices are left to cool outside of the reaction chamber. Generally, the susceptor with the substrates to be grown is introduced at room temperature, typically from 15° C. to 30° C.
The bar of the tool may be made of metal or a non-metallic material or, in any case, a material which is particularly resistant and retains a sufficient rigidity at the temperatures mentioned above.
As regards the non-metallic materials, the preferred material is quartz which is not only very refractory, but also very inert; moreover, it has a fairly low cost.
As regards the metals, the preferred material is stainless steel; among the various stainless steels, an optimum choice consists in steels based on iron and characterized by a chrome content of 16-18%, nickel content of 10-14%, molybdenum content of 2-4% and carbon content less than 0.08%.
In order to make the stainless steel tool more refractory it is useful to envisage a coating layer; for this purpose, it is possible to use oxides, for example vanadium oxide or titanium oxide or zirconium oxide or tungsten oxide; alternatively, it is possible to use nitrides or carbides, for example of the same metals. This coating layer may be obtained advantageously by means of PVD (Physical Vapour Deposition).
It is also possible to envisage coating the steel tool with a layer of PTFE (polytetrafluoroethylene) or PEEK (polyetheretherketone) or similar materials, if the susceptor is not handled at temperatures which are too high.
The susceptor and the tool according to the present invention, as described above and claimed below, are suitable for use in an epitaxial reactor and, in particular, in an epitaxial reactor with heating of the susceptor by means of electromagnetic induction.
According to a particular aspect, the present invention also relates to an epitaxial reactor; this is characterized in that it comprises such a susceptor and such a tool. Moreover, it may also comprise a robot equipped with an arm on which the tool according to the present invention is mounted or engaged.
This reactor may be advantageously equipped with an automatic or semi-automatic system for handling susceptors; in this case it will comprise an electronic control system able to control the robot so as to grip the projecting part of the susceptor by means of the tool.
The susceptor and the tool according to the present invention, as described above and claimed below, are particularly suitable and advantageous for being used in an epitaxial reactor with a long, wide, low reaction chamber heated by means of electromagnetic induction such as that, for example, shown in
According to a preferred embodiment of the reactor according to the present invention, this comprises a reaction chamber having a substantially rectangular inlet with a height ranging between 20 mm and 40 mm; the electronic control system is able to control the movement of the robot so as to grip the projecting part of the susceptor, release the projecting part of the susceptor, introduce the susceptor into the reaction chamber and extract the susceptor from the reaction chamber; preferably, the inlet of the reaction chamber has a width ranging between 150 mm and 300 mm and the disc of the susceptor has a diameter 20-40 mm less than the width of the inlet.
With reference to
It is not easy, during loading and unloading, to obtain a perfect alignment between susceptor, recess of the cavity and tool. In order to compensate for slight misalignment between susceptor and tool, it is possible to envisage suitable dimensions and/or suitable shaping of the bar, in particular its slot and/or its recess. In order to compensate for slight misalignment between susceptor and recess of the cavity, it is possible to envisage that the recess of the cavity has flared edges and/or that the pin for guiding rotation has its upper end flared and/or the seat of the rotation guiding pin has its inlet opening flared.
Number | Date | Country | Kind |
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MI2005A00645 | Apr 2005 | IT | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2006/061318 | 4/5/2006 | WO | 00 | 10/12/2007 |