Disk Susceptor Radial Notches Thermal Stress Relaxation

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Solution Overview

Problem

Large-sized vapor-phase growth apparatus susceptors with complex shapes and temperature gradients in both radial and axial directions are prone to cracking or fracture, making existing solutions ineffective for preventing thermal stress, especially when scaling up to accommodate multiple substrates.

Innovation Solution

A disk-shaped susceptor with notches extending radially at its outer periphery and a thrust-up mechanism for the susceptor cover, allowing for efficient heat distribution and stress relaxation, reducing the risk of cracking and fracture while maintaining cost-effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the susceptor size is increased to accommodate multiple substrates, then the productivity is improved, but the susceptibility to thermal stress cracking increases due to complex shape and temperature gradients

Engineering Contradiction:
Improvenumber of substrates processedVSAvoidsusceptor cracking resistance
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The susceptor is divided into multiple independent susceptor units, each capable of supporting substrates. These segmented units can be independently heated and cooled, reducing thermal stress concentration and preventing cracking while maintaining the ability to process multiple substrates simultaneously.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Multiple susceptor units are arranged in a nested configuration within the processing chamber, allowing efficient space utilization for processing multiple substrates while each unit maintains its own thermal management characteristics, reducing overall thermal stress.

Inventive Principle:
Principle #7Nested doll (Nesting)

2Temperature

If heating is applied from the lower surface to heat the substrate, then the substrate temperature is improved, but the temperature difference between upper and lower surfaces causes thermal stress

Engineering Contradiction:
Improvesubstrate temperatureVSAvoidthermal stress in susceptor
Core Design Contradiction:
TemperatureVSStress or pressure

Solution Approach 1:

Different regions of the susceptor structure are assigned different thermal properties. The lower surface is designed for efficient heat input while the upper surface and side walls incorporate thermal management features that promote uniform temperature distribution, reducing thermal gradients and stress.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The heating approach is extended from one-dimensional (lower surface only) to multi-dimensional thermal management, incorporating heating and cooling capabilities at multiple locations and orientations of the susceptor structure to achieve uniform temperature distribution.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

3Manufacturing precision

If the susceptor is designed with complex shape for rotating and revolving operation, then the uniformity of thin film growth is improved, but the manufacturing cost and cracking risk increase

Engineering Contradiction:
Improvethin film uniformityVSAvoidsusceptor manufacturing cost
Core Design Contradiction:
Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The complex rotating and revolving motion is achieved through multiple simpler susceptor units, each with simpler geometry. This segmentation reduces manufacturing complexity and cost for each unit while the collective arrangement achieves the desired thin film uniformity through coordinated motion.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Multiple susceptor units are combined in a coordinated system where their individual simpler motions merge to achieve the complex orbital and rotational patterns needed for uniform thin film deposition, reducing the complexity of individual components.

Inventive Principle:
Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution effectively prevents cracking and extends the lifespan of the susceptor by relaxing internal thermal stress, ensuring uniform temperature distribution and reducing manufacturing costs through optimized design and component placement.

Implementation Method 1

heating is performed from the lower surface side of the susceptor to heat the substrate to a high temperature

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

raw material gas flows on the upper surface side of the susceptor, the upper surface side of the susceptor is deprived of heat by raw material gas

Methodology Applied
Scientific EffectConvection cooling: Convection

Implementation Method 3

the susceptor has a plurality of notches extending in a radial direction at an outer periphery and/or a periphery of the opening

Methodology Applied
Scientific EffectStress relaxation: Stress Relaxation

Data Source

PatentUS9109303B2Susceptor and vapor-phase growth apparatus
Publication Date: 2015.08.18 NIPPON SANSO CORP
  • US9109303B2 patent drawing
  • US9109303B2 patent drawing
  • US9109303B2 patent drawing

AI summary

The present invention provides a susceptor which is rotatably provided in a chamber and has a plurality of substrate mounting parts, and a substrate on which a thin film is deposited is rotatably mounted on the substrate mounting part, andthe susceptor has a disk-shape wherein there is an opening at an inner periphery of the susceptor, into which a rotating shaft to rotate the susceptor is inserted, and the susceptor has a plurality of notches extending in a radial direction at an outer periphery and/or a periphery of said opening.