阅读说明：本技术 隔膜、阀、以及隔膜的制造方法 (Diaphragm, valve, and method for manufacturing diaphragm ) 是由 近藤研太 稻田敏之 中田知宏 渡边一诚 中田朋贵 于 2020-04-06 设计创作，主要内容包括：本发明提供一种能够适当控制在半导体的制造中进入到工艺腔室内的尘粒的尺寸的技术。隔膜(30)具备：金属制的薄板(31)、以及在薄板(31)的一侧的面(接液面(31A))的整体上形成的薄膜层(32)。薄膜层(32)的表面粗糙度的最大高度Rmax比0.1μm小。(The present invention provides a technique capable of appropriately controlling the size of dust particles entering a process chamber in the manufacture of a semiconductor. A separator (30) is provided with: a thin plate (31) made of metal, and a thin film layer (32) formed on the whole of one surface (liquid contact surface (31A)) of the thin plate (31). The maximum height Rmax of the surface roughness of the thin film layer (32) is smaller than 0.1 [ mu ] m.)

1. A separator is provided with: a metal thin plate; and a thin film layer formed on the entire one surface of the thin plate.

2. The separator according to claim 1, wherein the maximum height Rmax of the surface roughness of the thin film layer is smaller than 0.1 μm.

3. The separator according to claim 2, wherein the maximum height Rmax of the surface roughness of the thin film layer is smaller than 0.02 μm.

4. The separator according to claim 3, wherein the maximum height Rmax of the surface roughness of the thin film layer is smaller than 0.01 μm.

5. The separator according to any one of claims 1 to 4, wherein the thin film layer is a carbon film or a fluororesin film.

6. The separator according to claim 5, wherein the carbon film is composed of DLC.

7. A valve, comprising:

a valve body formed with a fluid passage;

a valve seat provided to the valve body; and

the diaphragm of any one of claims 1 to 6, which opens and closes the fluid passage by abutting against and moving away from the valve seat,

the membrane layer of the diaphragm is located on the valve seat side.

8. A method for manufacturing a separator having a thin metal plate and a thin film layer,

the thin plate is formed into a spherical shell shape,

the thin film layer having a maximum height Rmax of surface roughness smaller than 0.1 μm is formed on the entire concave surface of the thin plate.

Technical Field

The present disclosure relates to a diaphragm used in a semiconductor manufacturing apparatus or the like, a valve, and a method of manufacturing a diaphragm.

Background

As semiconductors become more sophisticated, proper control of the size of dust particles entering the process chamber is required. In order to suppress the entry of dust particles into the process chamber, a diaphragm in which a thin film layer is formed on a substrate has been proposed.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open publication No. 2004-60741

Disclosure of Invention

Technical problem to be solved

However, the diaphragm of patent document 1 does not consider the surface roughness of the thin film layer, and the size of dust particles entering the process chamber in the manufacture of a semiconductor cannot be appropriately controlled.

Accordingly, an object of the present disclosure is to provide a technique capable of appropriately controlling the size of dust particles entering a process chamber in the manufacture of semiconductors.

(II) technical scheme

In order to solve the above object, one aspect of the present disclosure is a separator including: a metal thin plate and a thin film layer formed on the whole of one surface of the thin plate. The maximum height Rmax of the surface roughness of the thin film layer is smaller than 0.1 μm.

The maximum height Rmax of the surface roughness of the thin film layer may be smaller than 0.02 μm.

The maximum height Rmax of the surface roughness of the thin film layer may be smaller than 0.01 μm.

The thin film layer may be a carbon film or a fluororesin film.

The carbon film may be made of DLC.

One aspect of the present disclosure is a valve including: a valve body formed with a fluid passage; a valve seat provided in the valve body; and the diaphragm that opens and closes the fluid passage by abutting against and separating from the valve seat, wherein the thin film layer of the diaphragm is positioned on the valve seat side.

One embodiment of the present disclosure is a method for manufacturing a separator, the separator including a metal thin plate and a thin film layer, the thin plate being molded into a spherical shell shape, the thin film layer having a maximum height Rmax of surface roughness smaller than 0.1 μm being formed on the entire concave surface of the thin plate.

(III) advantageous effects

According to the present disclosure, a technique capable of appropriately controlling the size of dust particles entering a process chamber in the manufacture of semiconductors can be provided.

Drawings

Fig. 1 is a sectional view of a valve in an open state of an embodiment.

Fig. 2 is an enlarged cross-sectional view of the vicinity of the diaphragm in the valve in the closed state.

Fig. 3(a) is a cross-sectional view of the thin plate and the film layer located closest to the seat portion, and (b) is an enlarged cross-sectional view of a part of the thin plate and the film layer of (a).

Detailed Description

A diaphragm 30 and a valve 1 according to an embodiment of the present disclosure will be described with reference to the drawings.

Fig. 1 is a sectional view of a valve 1 in an open state according to the present embodiment.

As shown in fig. 1, the valve 1 includes: a valve body 10, and an actuator 20. In the following description, the actuator 20 side of the valve 1 is referred to as the upper side, and the valve body 10 side is referred to as the lower side.

[ valve body 10]

The valve body 10 includes: the valve body 11, a seat 12 as a valve seat, a cover 13, a diaphragm 30, a presser foot joint 14, a diaphragm presser foot 15, a supporter 16, and a compression coil spring 17.

The valve body 11 is formed with: a valve chamber 11a, and an inlet passage 11b and an outlet passage 11c communicating with the valve chamber 11 a. The resin seat 12 is annular and is provided on the valve body 11 at a peripheral edge where the valve chamber 11a communicates with the inlet passage 11 b. As shown in fig. 2, the top surface 12A of the seat 12 is planar. The inlet passage 11b and the outlet passage 11c correspond to fluid passages.

As shown in fig. 1, the cap 13 is a substantially cylindrical shape having a cover, and is fixed to the valve body 11 so as to cover the valve chamber 11a by screwing the lower end portion thereof to the valve body 11.

The diaphragm 30 serving as a valve body is held by being pressed against the bottom surface of the valve chamber 11a forming the valve body 11 by a presser foot joint 14 disposed at the lower end of the cover 13. The fluid passage is opened and closed by the separation and contact (pressure contact) of the diaphragm 30 with respect to the seat 12. The detailed structure of the diaphragm 30 will be described later.

The diaphragm presser foot 15 is provided above the diaphragm 30 and configured to be capable of pressing the center portion of the diaphragm 30. The diaphragm presser foot 15 is fitted to the supporter 16.

The support 16 is substantially cylindrical and is disposed so as to be movable up and down in the cover 13. A rod 23B described later is screwed to the upper portion of the support 16.

The compression coil spring 17 is provided in the cover 13 and constantly biases the supporter 16 downward. The valve 1 is held in a closed state by the compression coil spring 17 at a normal time (when the actuator 20 is not operated).

[ actuator 20]

The actuator 20 is pneumatically driven, has a substantially cylindrical shape as a whole, and includes: a sleeve 21, a partition disc 22, a first piston portion 23, and a second piston portion 24.

The sleeve 21 has: a lower sleeve 21A, and an upper sleeve 21B having a lower end portion screwed to an upper end portion of the lower sleeve 21A. The lower sleeve 21A is substantially cylindrical with steps. The outer periphery of the lower end portion of the lower sleeve 21A is screwed to the inner periphery of the through hole of the cap 13. The upper sleeve 21B is substantially cylindrical with a cover. A fluid introduction passage 21c is formed in the upper end portion of the upper sleeve 21B.

A nut 25 is screwed to the outer periphery of the lower end portion of the lower sleeve 21A. The nut 25 abuts on the cover 13, and rotation of the lower sleeve 21A relative to the cover 13 is suppressed.

The partition plate 22 is substantially disc-shaped and is immovably provided in the sleeve 21.

The first piston portion 23 has: a first piston 23A, a rod 23B, and a first upper extension 23C. The first piston 23A is provided between the partition plate 22 and the lower sleeve 21A, and has a substantially disk shape. The lower sleeve 21A and the first piston 23A form a first pressure chamber S1.

The rod 23B extends downward from the central portion of the first piston 23A. The lower end of the rod 23B is screwed to the support 16. The first upper extension 23C extends upward from the center of the first piston 23A and penetrates the partition plate 22.

The first piston 23A, the rod 23B, and the first upper extension portion 23C form a first fluid inlet passage 23d extending in the vertical direction and communicating with the first pressure chamber S1 and the second pressure chamber S2.

The second piston portion 24 has: a second piston 24A, and a second upper extension 24B. The second piston 24A is provided between the partition plate 22 and the upper sleeve 21B, and has a substantially disk shape. The second pressure chamber S2 is formed by the partition disk 22 and the second piston 24A. The upper end of the first upper extension 23C is connected to the second piston 24A.

The second upper extension portion 24B extends upward from the center portion of the second piston 24A and is inserted into the fluid introduction passage 21 c. The second upper extension 24B is provided with a second fluid inlet passage 24c communicating with the fluid introduction passage 21c and the first fluid inlet passage 23 d.

[ opening/closing operation of valve 1 ]

Next, the opening and closing operation of the valve 1 of the present embodiment will be described.

Fig. 2 is an enlarged sectional view of the vicinity of the diaphragm 30 in the valve 1 in the closed state.

In the valve 1 of the present embodiment, in a state where the driving fluid does not flow into the first and second pressure chambers S1 and S2, as shown in fig. 2, the holder 16 and the rod 23B are positioned at the bottom dead center (close to the valve body 11) by the biasing force of the compression coil spring 17, the diaphragm 30 is pressed by the diaphragm presser foot 15, the lower surface of the diaphragm 30 is pressed against the seat 12, and the valve 1 is in a closed state. That is, the valve 1 is in a closed state in a normal state (a state where the driving fluid is not supplied).

Then, the driving fluid is supplied from a driving fluid supply source, not shown, to the valve 1. Thereby, the driving fluid is supplied to the valve 1. The drive fluid passes through the fluid introduction passage 21c via a breather pipe and a pipe joint, not shown, and flows into the first and second pressure chambers S1, S2 through the first and second fluid inflow passages 23d, 24 c. When the driving fluid flows into the first and second pressure chambers S1, S2, the first and second pistons 23A, 24A rise against the urging force of the compression coil spring 17. Thereby, the supporter 16, the diaphragm presser foot 15, and the rod 23B move to the top dead center and are separated from the valve body 11, the diaphragm 30 is moved upward by the elastic force and the pressure of the fluid (gas), the inflow passage 11B communicates with the outflow passage 11c, and the valve 1 is opened.

In order to change the valve 1 from the open state to the closed state, a three-way valve (not shown) is switched to a flow in which the drive fluid is discharged to the outside from the actuator 20 (first and second pressure chambers S1, S2) of the valve 1. Thereby, the driving fluid in the first and second pressure chambers S1, S2 is discharged to the outside through the first and second fluid inflow passages 23d, 24c and the fluid introduction passage 21 c. Thereby, the holder 16 and the rod 23B are moved to the bottom dead center by the biasing force of the compression coil spring 17, and the valve 1 is closed.

[ separator 30]

Next, the structure of the diaphragm 30 will be described.

The diaphragm 30 is spherical shell-shaped and naturally has an arc shape protruding upward. The separator 30 includes, for example: a plurality of metallic sheets 31 and a film layer 32. Each thin plate 31 is made of nickel-cobalt alloy, stainless steel, or the like, and is formed in a spherical shell shape by cutting a flat plate-like material into a circular shape and bulging the center portion upward.

Fig. 3(a) is a cross-sectional view of the thin plate 31 and the film layer 32 located closest to the seat 12, and (b) is an enlarged cross-sectional view of a part of the thin plate 31 and the film layer 32 of (a).

The thin film layer 32 is formed on the entire liquid-contacting surface 31A, which is a concave surface of the thin plate 31. The liquid-receiving surface 31A corresponds to one surface of the thin plate 31. The thin film layer 32 is, for example, a carbon film or a fluorine resin film. The Carbon film is, for example, a DLC (Diamond like Carbon) film, and the fluorine resin film is, for example, a polytetrafluoroethylene resin (PTFE), a tetrafluoroethylene hexafluoropropylene copolymer (FEP), a tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA).

The film thickness of the thin film layer 32 is 2 to 4 μm, and the maximum height Rmax of the surface roughness is smaller than 0.1 μm. That is, the maximum height Rmax of the surface roughness of the thin film layer 32 is larger than 0 μm and smaller than 0.1 μm. The maximum height Rmax of the surface roughness of the thin film layer 32 is preferably less than 0.02 μm, and more preferably less than 0.01 μm. Here, the maximum height (Rmax) of the surface roughness of the thin film layer 32 is "maximum height (Rmax)" specified in JIS B0601 (2001). The surface roughness of the liquid-receiving surface 31A of the thin plate 31 is, for example, ra0.05 μm.

Next, a method for manufacturing the separator 30 will be described.

A plurality of disc-shaped and flat-plate-shaped thin plates (raw materials) are prepared, and these thin plates are laminated and bonded to each other integrally with an adhesive or the like. The integrated sheets are fixed to a jig of a press device, and pressed by a punch at the center to be molded into a spherical shell shape.

Next, the plurality of molded thin plates are fixed to a jig of a film forming apparatus, and a thin film layer 32 is formed on the concave surface of the thin plate 31. When the thin film layer 32 is a DLC film, the thin film layer 32 is formed by Physical Vapor Deposition (PVD) and/or Chemical Vapor Deposition (CVD). For example, magnetron sputtering is combined with PACVD (plasma assisted CVD) to form a DLC film. When the thin film layer 32 is a PFA film, electrostatic coating or hot-pressing film is used to form the film. Further, by changing the film formation conditions, the maximum height Rmax of the surface roughness of the thin film layer 32 can be controlled, and the thin film layer 32 having the maximum height Rmax as described above can be obtained. In addition, in the DLC coating, a vapor deposition method is used without spray coating or dip coating, and thereby the DLC coating is selectively attached to the concave portion of the coated surface (the liquid contact surface 31A of the thin plate 31), and the coated surface of the product (the thin film layer 32) is made smoother.

According to the valve 1 including the diaphragm 30 of the present embodiment described above, the film thickness of the thin film layer 32 is 2 to 4 μm, and the maximum height Rmax of the surface roughness is smaller than 0.1 μm. Therefore, during cleaning, it is possible to prevent dust particles having a particle size of 0.1 μm or more from being captured and accumulated on the surface of the thin film layer 32. Therefore, in the manufacture of semiconductor, the dust particles with the particle diameter of more than 0.1 μm can be prevented from entering the process chamber. Therefore, according to the valve 1 including the diaphragm 30 of the present embodiment, the size of dust particles entering the process chamber during semiconductor manufacturing can be appropriately controlled. For example, when a semiconductor having a line width of 100nm is manufactured using a conventional semiconductor manufacturing apparatus, dust particles having a particle diameter v of 0.1 μm or more can be prevented from entering the process chamber during the manufacturing process by using the valve 1 provided with the diaphragm 30. Therefore, the yield of the semiconductor can be improved as compared with the case of using the conventional semiconductor manufacturing apparatus.

The maximum height Rmax of the surface roughness of the thin film layer 32 is preferably less than 0.02 μm, and more preferably less than 0.01 μm. Thus, in the current semiconductor manufacturing process with a line width of 0.02 μm, dust particles having a size of 0.02 μm or more in particle diameter can be suppressed from entering the process chamber. In addition, in a semiconductor manufacturing process of a new generation having a line width of 0.01 μm, dust particles having a particle diameter of 0.01 μm or more can be prevented from entering a process chamber.

Since the thin film layer 32 is a carbon film or a fluororesin film, and the carbon film is made of DLC, the separator 30 having low friction, excellent abrasion resistance, and excellent corrosion resistance can be provided, and transfer of the seat portion 12 to the separator 30 can be suppressed.

The method for manufacturing the separator 30 is to mold the thin plate 31 into a spherical shell shape, and to form the thin film layer 32 having a maximum height Rmax of surface roughness smaller than 0.1 μm on the entire concave surface of the thin plate 31. According to this manufacturing method, the thin plate 31 is not molded after the thin film layer 32 is formed, and therefore the separator 30 having the thin film layer 32 with the surface roughness having the maximum height Rmax smaller than 0.1 μm can be reliably provided.

Further, the present disclosure is not limited to the above-described embodiments. Those skilled in the art may make various additions, modifications, and the like within the scope of the present disclosure.

The thin plate 31 is a plurality of sheets, but may be a single sheet. The top surface 12A of the seat portion 12 is planar, but may be a curved surface that is convex upward (the cross-sectional shape in the radial direction is an R surface (circular arc surface)). The actuator 20 is pneumatically driven, but may be electromagnetically driven or driven by a piezoelectric element.

Description of the reference numerals

1: a valve; 11: a valve body; 11 b: an inflow path; 11 c: an outflow path; 12: a seat portion; 30: a diaphragm; 31: a thin plate; 31A: receiving the liquid level; 32: a thin film layer.