Chemical vapor deposition apparatus
First Claim
1. A reactor for growing epitaxial layers on a substrate comprising a reactor chamber, a substrate carrier rotatably mounted within said reactor chamber, whereby at least one of said substrates can be mounted on said substrate carrier, a first gas inlet, a second gas inlet, an injector for injecting said first and second gases into said reactor chamber in a first direction towards said substrate carrier, and a gas separator disposed between said first and second gas inlets and said injector for separately maintaining said first and second gases in a single plane parallel to said substrate carrier for separately distributing said first and second gases within said single plane transverse to said first direction and over the surface of said injector, said first and second gas inlets supplying said first and second gases directly to said gas separator substantially in said first direction whereby said first and second gases are separately maintained until said first and second gases approach said substrate carrier.
1 Assignment
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Accused Products
Abstract
Reactors for growing epitaxial layers on substrates are disclosed including rotatable substrate carriers and injectors for injecting gases into the reactor towards the substrates on the carriers and including a gas separator for separately maintaining various gases between gas inlets and the injector. Various reactor embodiments are disclosed including removable gas separators, and particular injectors which include cooling channels, as well as flow restrictors mounted within the reactors to restrict the flow of the gases to the substrates from the injector, and heaters mounted within the rotatable shell holding the substrate carriers so that the heaters can be accessed and removed through a lid forming a wall of the reactor.
104 Citations
58 Claims
- 1. A reactor for growing epitaxial layers on a substrate comprising a reactor chamber, a substrate carrier rotatably mounted within said reactor chamber, whereby at least one of said substrates can be mounted on said substrate carrier, a first gas inlet, a second gas inlet, an injector for injecting said first and second gases into said reactor chamber in a first direction towards said substrate carrier, and a gas separator disposed between said first and second gas inlets and said injector for separately maintaining said first and second gases in a single plane parallel to said substrate carrier for separately distributing said first and second gases within said single plane transverse to said first direction and over the surface of said injector, said first and second gas inlets supplying said first and second gases directly to said gas separator substantially in said first direction whereby said first and second gases are separately maintained until said first and second gases approach said substrate carrier.
- 9. A reactor for growing epitaxial layers on a substrate comprising a reactor chamber, a substrate carrier rotatably mounted within said reactor chamber, whereby at least one of said substrates can be mounted on said substrate carrier, a gas inlet, an injector for injecting said gas into said reactor chamber towards said substrate carrier in a first direction, and a removable gas separator removably disposed between said gas inlet and said injector for maintaining said gas in a predetermined portion of said gas separator, whereby said gas separator can be replaced with a different gas separator, said gas separator including a gas receiving portion for receiving said gas from said gas inlet substantially in said first direction, a gas chamber for distributing a quantity of said gas in a direction substantially transverse to said first direction prior to entry of said gas into said injector, and wall means separating said gas receiving portion from said gas chamber, said wall means including an aperture for permitting said gas to pass from said gas receiving portion to said gas chamber.
- 20. A reactor for growing epitaxial layers on a substrate comprising a reactor chamber, a substrate carrier rotatably mounted within said reactor chamber, whereby at least one of said substrates can be mounted on said substrate carrier, a first gas inlet, a second gas inlet, a carrier gas inlet, an injector for injecting said first and second gases and said carrier gas into said reactor chamber towards said substrate carrier in a first direction, and a gas separator for separately maintaining said first and second gases and said carrier gas between said gas inlet and said injector and for separately distributing said first and second gases and said carrier gas within a single plane transverse to said first direction and over the surface of said injector whereby said first and second gases and said carrier gas are separately maintained after said first and second gases and said carrier gas have exited from said injector towards said substrate carrier with said carrier gas disposed between said first and second gases.
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27. A reactor for growing epitaxial layers on a substrate comprising a reactor chamber, a substrate carrier rotatably mounted within said reactor chamber, whereby at least one of said substrates can be mounted on said substrate carrier, a gas inlet, an injector for injecting said gas into said reactor chamber toward said substrate carrier, said substrate carrier comprising a substantially enclosed rotatable shell defining an inner space, said rotatable shell including an upper end facing said injector, and including a removable substrate support mounted on said upper end of said rotatable shell for rotation therewith so as to provide an upper end wall for said rotatable shell and thereby creating said substantially enclosed inner space, and a heater for heating said substrate carrier, said heater being disposed within said rotatable shell, said reactor chamber including an access port for gaining access to said inner space defined by said rotatable shell whereby said heater can be accessed and removed through said access port.
- 28. A reactor for growing epitaxial layers on a substrate comprising a reactor chamber, a substrate carrier rotatably mounted within said reactor chamber, whereby at least one of said substrates can be mounted on said substrate carrier, a gas inlet, and an injector for injecting said gas into said reactor chamber towards said substrate carrier, said injector including a plurality of coolant passages extending across said injector and a plurality of longitudinally extending gas apertures comprising a plurality of elongated slots extending across said injector and alternating with said plurality of coolant passages, whereby said gas is cooled by at least two of said coolant passages as it passes through at least one of said plurality of longitudinally extending gas apertures into said reactor chamber.
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38. A reactor for growing epitaxial layers on a substrate comprising a reactor chamber, a substrate carrier rotatably mounted within said reactor chamber, said substrate carrier having a predetermined diameter, whereby at least one of said substrates can be mounted on said substrate carrier, a gas inlet, an injector for injecting said gas into said reactor chamber toward said substrate carrier, whereby said gas and rotation of said substrate carrier creates a boundary layer of said gas above said rotating substrate carrier having a predetermined height, and a flow restricter mounted within said reactor chamber between said injector and said substrate carrier for restricting the flow of said gas therebetween, said flow restricter having a first end corresponding to said injector and a second end adjacent to said substrate carrier and defining a substantially constant inner diameter from said first end of said flow restricter to a location spaced about 0.5 to 2.0″
- from said substrate carrier, said inner diameter substantially corresponding to said predetermined diameter of said substrate carrier.
- View Dependent Claims (39, 40, 41, 42, 43, 44)
- 45. A reactor for growing epitaxial layers on a substrate comprising a reactor chamber, a substrate carrier rotatably mounted within said reactor chamber, whereby said substrate can be mounted on said substrate carrier, a gas inlet, an injector for injecting said gas into said reactor chamber toward said substrate carrier, a flow restricter mounted within said reactor chamber between said injector and said substrate carrier for restricting the flow of said reactant gas therebetween, said flow restricter having a first end corresponding to said injector and a second end adjacent to said substrate carrier and defining an inner diameter at said first end substantially corresponding to said predetermined diameter of said substrate carrier, said inner diameter of said flow restricter at said first end thereof including substantially the entire length of said flow restricter, said flow restricter further including a cooling chamber, and control means associated with said cooling chamber for reducing recirculation within said reactor.
- 48. A reactor for growing epitaxial layers on a substrate comprising a reactor chamber, a substrate carrier rotatably mounted within said reactor chamber, whereby at least one of said substrates can be mounted on said substrate carrier, a gas inlet, an injector for injecting said gas into said reactor chamber toward said substrate carrier, said substrate carrier comprising a substantially enclosed rotatable shell defining an inner space, first pressure means for maintaining a first pressure inside said reactor chamber, second pressure means for maintaining a second pressure inside of said rotatable shell, said first pressure being greater than said second pressure, and a heater for heating said substrate carrier, said heater being disposed within said rotatable shell, said reactor chamber including an access port for gaining access to said inner space defined by said rotatable shell whereby said heater can be accessed and removed through said access port.
- 54. A reactor for growing epitaxial layers on a substrate comprising a reactor chamber, a substrate carrier rotatably mounted within said reactor chamber, whereby at least one of said substrates can be mounted on said substrate carrier, a gas inlet, an injector for injecting said gas into said reactor chamber towards said substrate carrier, said substrate carrier comprising a rotatable shell defining an inner space and including an inner surface and an outer surface, rotation means for rotating said rotatable shell within said reactor chamber, and cooler for cooling said reactor chamber, said cooling means including an inner cooling member for cooling said inner surface of said rotatable shell and an outer cooling member for cooling said outer surface of said rotatable shell.
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58. A reactor for growing epitaxial layers on a substrate comprising a reactor chamber, a substrate carrier rotatably mounted within said reactor chamber, whereby at least ones of said substrates can be mounted on said substrate carrier, a gas inlet, an injector for injecting said gas into said reactor chamber toward said substrate carrier, said substrate carrier comprising a substantially enclosed rotatable shell defining an inner space, said rotatable shell including an upper end wall facing said injector, and including a removable substrate support mounted on said upper end wall for rotation therewith, and a heater for heating said substrate carrier, said heater being disposed within said rotatable shell, said reactor chamber including an access port for gaining access to said inner space defined by said rotatable shell whereby said heater can be accessed and removed through said access port.
Specification