A floating substrate reactor allows heat treatment of a series of semiconductor
substrates, one by one. The heat treatment occurs while flowing gas suspends a
substrate between two heated surfaces of the reactor. The two heated surfaces each
have multiple heating zones. The heating zones are heated to desired temperature(s)
and a substrate is then loaded into the reactor for heat treatment. Upon loading,
the relatively cold substrate absorbs heat and cools the process chamber. A heat
spike, which can be varied, is applied to the heating zones to heat the reactor
to the desired temperature again. The substrate, however, is unloaded from the
reactor before the temperatures of the heating zones have reached the desired temperature.
After the heating zones have reached the desired temperature, the next substrate
in the series of substrates is loaded into the reactor for heat treatment. The
heating rate of each heating zone is independently controlled by two nested control
loops in a cascade temperature control configuration, permitting differences in
the heating rates of the heating zone to be accounted for, thus allowing a uniform
temperature or predetermined gradient to be established across all the heating
zones. The intensity of the heat spike is recalculated after the introduction of
each substrate, using the heating behavior of the previous heat spike as a calculation
input, to more accurately heat the heating zones to the desired temperature. The
variability of the heat spike intensity from substrate to substrate also allows
the throughput of the heat treatment apparatus to be varied.