A substrate processing equipment comprises two pod supporting stages and two independently operable pod door openers. Each pod supporting stage is capable of placing thereon a pod for containing substrates therein. Each pod door openers having means for permitting access to the substrates inside the pod placed on a corresponding pod supporting stage.
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7. A substrate processing equipment comprising:
at least one two pod door doors opening mechanism for permitting access to substrates disposed inside a pod having a door;
wherein each of the pod door opening mechanism moves the door of the pod horizontally from a position where the door of the pod is closed to a retreated position where the pod is completely open thereby allowing substrates to be unloaded from the pod.
1. A substrate processing equipment comprising:
at least two pod supporting stages, each for placing thereon a pod for containing substrates therein, the pod having a door;
at least two independently operable pod doors opening mechanisms, each for permitting access to substrates inside the pod placed on a corresponding one of the pod supporting stages; and
wherein each of the pod door opening mechanisms horizontally removes the door from the corresponding pod to thereby allow substrates disposed inside of the corresponding pod to be unloaded therefrom.
9. A substrate processing method for use in a substrate processing equipment including at least two pod supporting stages, each for placing thereon a pod for containing substrates therein, the pod having a door, the method comprising the steps of:
(a) placing a first pod on one pod supporting stage;
(b) opening a door of the first pod only independently of a door of a second pod in substantially horizontal directions;
(c) loading or unloading substrates to or from the first pod; and
(d) placing a the second pod on another pod supporting stage during the loading or unloading step (c).
8. A substrate processing equipment comprising:
a pod supporting stage for placing thereon a pod for containing substrates therein, the pod having an opening;
a mapping apparatus mounted on the pod supporting stage for detecting the locations of substrates in the pod placed on the pod supporting stage through the opening of the pod;
a substrate handling apparatus for unloading substrates from the pod placed on the pod supporting stage through the opening of the pod; and
wherein the mapping apparatus pivotally moves between a mapping position at which a mapping process is carried out and a standby position located away from the opening of the pod to allow a substrates unloading process to be carried out through the opening.
0. 19. A substrate processing method for use in a substrate processing equipment including at least two pod supporting stages, each for placing thereon a pod for containing substrates therein, the pod having a door, the method comprising the steps of:
(a) placing a first pod on one pod supporting stage;
(b) opening a door of the first pod only in substantially horizontal directions;
(c) loading or unloading substrates to or from the first pod;
(d) placing a second pod on another pod supporting stage during the loading or unloading step (c);
(e) opening a door of the second pod during the loading or unloading step (c); and
(f) detecting a position of the substrate in the second pod during the loading or unloading step (c).
0. 18. A substrate processing method for use in a substrate processing equipment including at least two pod supporting stages, each for placing thereon a pod for containing substrates therein, the pod having a door, the method comprising the steps of:
(a) placing a first pod on one pod supporting stage;
(b) opening a door of the first pod only in substantially horizontal directions;
(c) loading or unloading substrates to or from the first pod;
(d) placing a second pod on another pod supporting stage during the loading or unloading step (c);
(e) opening a door of the second pod during the loading or unloading step (c);
(f) loading or unloading substrates to or from the second pod; and
(g) closing the door of the first pod in substantially horizontal directions during the loading or unloading step (f).
0. 17. A substrate processing method for use in a substrate processing equipment including at least two pod supporting stages, each for placing thereon a pod for containing substrates therein, the pod having a door, the method comprising the steps of:
(a) placing a first pod on one pod supporting stage;
(b) opening a door of the first pod only in substantially horizontal directions;
(c) loading or unloading substrates to or from the first pod;
(d) placing a second pod on another pod supporting stage during the loading or unloading step (c); and
(e) opening a door of the second pod from a position where the door of the second pod is closed to a retreated position where the second pod is open thereby allowing substrates to be loaded or be unloaded from the second pod during the loading or unloading step (c).
0. 10. A substrate processing equipment comprising:
at least two pod supporting stages, each for placing thereon a pod for containing a plurality of substrates therein, the pod having an opening for loading and unloading the substrates and a door for opening and closing the opening of the pod wherein at least two substrate loading ports for loading and unloading the plurality of substrates out of the opening of the pod are disposed vertically; and
at least two pod doors opening mechanisms, each for opening and closing the opening of the pod containing closures smaller than width in the vertical direction in the door at intervals in the vertical direction and horizontal guide rails which are parallel with the opening of the pod, provided at substrate loading ports, each for permitting access to substrates inside the pod placed on a corresponding one of the pod supporting stages,
wherein each of the closures moves the door horizontally with the opening of the opening of the pod in horizontal same direction independently by guide rails and the each of the closure moves the door horizontally with the opening of the closing of the pod in horizontal same direction independently by guide rails, such that each of the pod door opening mechanisms horizontally removes the door from the corresponding pod to thereby allow substrates disposed inside of the corresponding pod to be unloaded therefrom.
0. 16. A substrate processing method for use in a substrate processing equipment including at least two pod supporting stages, each for placing thereon a pod for containing a plurality of substrates therein, the pod having an opening for loading and unloading the substrates and a door, for opening and closing the opening of the pod wherein at least two substrate loading ports for loading and unloading the plurality of substrates out of the opening of the pod are disposed vertically smaller than width in the vertical direction in the door at intervals in the vertical direction,
at least two pod doors opening mechanisms, each for opening and closing the opening of the pod containing closures smaller than width in the vertical direction in the door at intervals in the vertical direction and horizontal guide rails which are parallel with the opening of the pod, provided at substrate loading ports, each for permitting access to substrates inside the pod placed on a corresponding one of the pod supporting stages, the method comprising the steps of:
(a) placing a first pod on one pod supporting stage;
(b) opening a door of the first pod only in substantially the first horizontal direction and in parallel with the opening of the pod by a first closure and a first guide rail;
(c) loading or unloading substrates to or from the first pod; and
(d) placing a second pod on another pod supporting stage during the loading or unloading step (c),
wherein the another pod door opening mechanism moves the door of the second pod the first horizontal direction and in parallel with the opening of the pod by a second closure and a second guide rail.
2. The substrate processing equipment of
3. The substrate processing equipment of
4. The substrate processing equipment of
5. The substrate processing equipment of
a substrate handling apparatus for loading substrates to a pod or unloading substrates from a pod placed on one of the pod supporting stages; and
a pod transferring apparatus for placing another pod on the other pod supporting stage while the substrate handling apparatus loads substrates to the pod or unloads substrates from the pod placed on said one of the pod supporting stages.
6. The substrate processing equipment of
0. 11. The substrate processing equipment of claim 10, further comprising:
an air cylinder for reciprocally operating the closure horizontally and in parallel with the opening of the pod, which are provided at each of the substrate loading ports.
0. 12. The substrate processing equipment of claim 10, wherein each of the substrate loading ports includes a mapping apparatus for detecting locations of the substrates in the pod placed thereon.
0. 13. The substrate processing equipment of claim 12, wherein the mapping apparatus moves between a mapping position at which a mapping process is carried out and a standby position located away from a pod entrance of the corresponding pod to allow a substrate loading or unloading process to be carried out through the pod entrance.
0. 14. The substrate processing equipment of claim 10, further comprising:
a substrate handling apparatus for loading substrates to a pod or unloading substrates from a pod placed on one of the pod supporting stages; and
a pod transferring apparatus for placing another pod on the other pod supporting stage while the substrate handling apparatus loads substrates to the pod or unloads substrates from the pod places on said one of the pod supporting stages.
0. 15. The substrates processing equipment of claim 10, wherein each pod door opening mechanism moves the door of the pod between a position where the door of the pod is closed and a retreated position where the corresponding pod is completely opened.
0. 20. The substrate processing method for use in a substrate processing equipment according to claim 17, wherein each of said at least two pod supporting stages is disposed vertically, the method further comprising: opening the door of the first pod in substantially horizontal and in parallel with the opening of the first pod in step (b); and opening the door of the second pod in substantially horizontal and in parallel with the opening of the second pod in step (e).
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Further, as shown in
As shown in
As shown in
Referring to
In operation, the pods 10 are loaded onto the pod stage 11 through the pod load/unload opening and then transferred by the pod handler 14 to predetermined positions on the pod shelf 12 for temporary storage as shown in
The two pod openers 20 are arranged to close the openings 22 such that the packing member 55 seals against the rear side wall of the bulkhead 21. One pod 10 is transferred from the pod shelf 12 to, e.g., the upper wafer loading port 13 by the pod handler 14 and disposed on the loading platform 27. The three alignment pins 28 on the loading platform 27 engage with the corresponding three holes (not shown) formed under the pod 10 to thereby complete the alignment of the pod 10 on the loading platform 27.
The pod 10 provided on the loading platform 27 is moved toward the bulkhead 21 by the extension of the air cylinder 26 in such a manner that the respective packing members 54 and 56 are airtightly in contact with the pod door 10a and the pod frame therearound as shown in
After completing the pod transferring process “A”, a negative pressure is applied through the air exhaust/supply pipes 47 inside the suction elements 46 so that the suction elements 46 hold the door 10a by vacuum suction. Thereafter, the keys 41 are rotated by the air cylinder 45 so that the coupling members 41a unlock the door 10a.
Next, the back/forth slider 34 is moved away from the bulkhead 21 by the rotary actuator 37 and then the angle-shaped slider 31 is moved away from the opening 22 by the air cylinder 32 so that the closure 40 holding the pod door 10a by the suction elements 46 is moved to a retreated position. By such movement of the closure 40, the door 10a is separated from the pod 10 and the pod is opened as shown in
Thereafter, as shown in
Next, the wafers in the pod 10 on the wafer loading port 13 are transferred to the wafer boat 8 by the wafer transfer assembly 15. The wafer transferring process described above is generally represented as a process “D” at after the first stage in
While the wafer transferring process “D” is performed at after the first stage, e.g., the upper wafer loading port 13, the pod transferring process “A”, the pod door opening process “B” and the mapping process “C” are sequentially carried out at the second stage, e.g., the lower wafer loading port 13. the The second wafer loading port 13 waits (process E “F”) until the wafer transferring process “D” at the first wafer loading port 13 is completed.
Accordingly, upon the completion of the wafer transferring process “D” of the first wafer loading port 13 at, for which the second stage is waiting (process “F”), the wafer transferring process “D” can be started at the second wafer loading port 13 as shown in
During the third stage shown in
The pod door closing process is carried out as follows. The closure 40 holding the pod door 10a is removed from the retreated position toward the opening 22 by the air cylinder 32 and then toward the empty pod 10 by the rotary actuator 37 to close the pod 10 by the pod door 10a thereafter, the keys 41 are rotated by the air cylinder 45 to actuate the locking mechanism of the pod door 10a. After locking, the negative pressure inside the suction element 46 is removed by supplying a positive pressure through the pipe 47 and the closure 40. The closure 40 remains in that position until the pod door opening process “B” is resumed.
The pod changing process “A” is carried out as follows. After the pod door 10a is restored on the empty pod 10 by the pod door closing process “E”, the loading platform 27 of the first wafer loading port holding the empty pod is moved away from the bulkhead 21 by the air cylinder 26. The empty pod 10 is then stored back to the pod shelf 12 and a new pod holding wafer therein is transferred to the first wafer loading port. Thereafter, the newly supplied pod is provided to the closure 40 in an identical manner as in the pod transferring process “A”. The remaining process “B”, “C” and “F” are identical to those of the second stage.
The wafer loading processes are repeated until the described number of wafers are loaded from the pods 10 to the wafer boat 8. After transferring the described number of wafers, the last two empty pods may be removed to the pod shelf 12 or stayed on the wafer loading ports 13. Alternatively, only one empty port 13 may remain at the one wafer loading port 13. The number of wafers which the wafer boat 8 can hold for one batch process is, e.g., 100 to 150, which is several times greater than that of wafers which one pod can contain therein, e.g., 25.
After the predetermined number of unprocessed wafers are loaded on the wafer boat 8, the boat elevator 7 lifts the wafer boat 8 into the process tube 4. When the wafer boat 8 is introduced into the process tube 4, a lower end opening of the process tube 4 is hermetically sealed by the boat receptacle 8a.
Next, the process tube 4 is evacuated through the exhaust pipe 6 to reduce the pressure therein down to a predetermined vacuum level. Thereafter, a desired wafer process, e.g., a diffusion or a CVD process, is carried out on the loaded wafers by controlling temperatures at desired levels by using the heater unit 3 while supplying predetermined process gases into the process tube 4 through the gas supply line 5.
After a predetermined processing time has elapsed, the wafer boat 8 holding processed wafers is discharged from the process tube 4 and returned to its initial position. During the period in which the wafer boat 8 is loaded into and unloaded from the process tube 4 and the wafers are processed in the process tube 4, either one or both of the pods 10 may be prepared at the corresponding wafer loading ports 13 in order to receive the processed wafers.
Thereafter, the wafer transfer assembly 15 transfers a portion of the processed wafers held in the wafer boat 8 to one empty pod 10 disposed on, e.g., the first wafer loading port 13 (upper loading port) with the door 10a opened. This process corresponds to the wafer transferring process “D” at the second stage shown in
While the wafer loading process “D” is carried out at the second wafer loading port, the pod door closing process “E”, the pod changing process “A”, the pod door opening process “B” and the waiting process “F” are carried out at the first wafer loading port as in the third stage of
The process “E”, “A”, “B” and “F” are identical to those described with respect to the wafer loading process from the pods 10 to the wafer boat 8, excepting that the pod changing process “A” represents the process transferring a pod containing the processed wafers to the pod shelf 12 from a wafer loading port and moving an empty pod from the pod shelf 12 to the wafer loading port 13.
In case all the empty pods have been transferred from the wafer loading ports 13 to the pod shelf 12 after loading all the wafers onto the boat 8, the processed wafer unloading process can be accomplished as follows. First, one empty pod is transferred from the pod shelf 12 to one of the wafer loading ports and the pod door 10a thereof is opened. These correspond to the process “A” and “B” of the first stage in
Thereafter at the second stage, the wafer transferring process “D” is carried out at the first wafer loading port 12, while the process “A”, “B” and “F” are sequentially performed at the second wafer loading port. Then, the process at the third stage can be carried out as described above.
The processes are repeated until transferring all the processed wafers from the wafer boat 8 to the empty pods, which in turn are returned to the pod shelf 12.
As described above, since the wafer transfer assembly 15 can transfer the processed wafers from the wafer boat 8 to the pods 10 continuously without having to wait for the replacement of the pods 10 on the wafer loading ports 13, the throughput of semiconductor processing equipment 1 can be substantially increased.
The pods 10 containing the processed wafers are temporarily stored in the pod shelf 12 and then transferred to the pod stage 11 by the pod handler 14. Next, the pods on the pod stage 11 are transferred through the pod load/unload opening (not shown) to another equipment for a subsequent process and new pods containing unprocessed wafers are charged on the pod stage 11.
The processes of transferring pods between the pod shelf 12 and the pod stage 11 and charging and discharging pods into and from the semiconductor processing equipment 1 can be carried out while wafers are being processed in the process tube 4 and transferred between the wafer boat 8 and the pods 10 on the wafer loading ports 13. As a result, the total process time of the semiconductor processing equipment 1 can be reduced.
Referring to
The wafer transferring sequence in accordance with the second embodiment of the present invention will be described with reference to
Immediately thereafter at the second stage, wafer transferring from the first pod to the wafer boat 8 (process “D”) starts and, at the same time, a second pod containing the unprocessed wafers are transferred to a second wafer loading port (process “A”) and waits until the wafer transferring process “D” at the first wafer loading port is completed (process “F”).
At the third stage, the door of the second pod is opened (process “B”) and the wafers therein are transferred to the boat 8 (process “D”) and the door is restored on the empty first pod (process “E”), which is then replaced with another pod carrying unprocessed wafer (process “A”), the new pod remaining at the first wafer loading port until the wafer loading process at the second wafer loading port is completed (process “F”). The processes described in connection with the third stage are alternately carried out until all the required wafers for one batch process are transferred to the wafer boat 8.
As described above in the second embodiment of the present invention, the pod transferring process “A” and the pod changing process “A” for one wafer loading port are carried out during the wafer transferring process “D” at the other wafer loading port; and the pod door opening process “B” for one wafer loading port and the pod door closing process “E” for the other wafer loading port are simultaneously conducted.
The process sequence of the second embodiment for transferring processed wafers to empty pods is identical to that for transferring unprocessed wafers to the wafer boat 8, excepting that the pod changing process “A” in the process sequence for transferring processed wafers represents the process of transferring a pod containing the processed wafers from a wafer loading port to the pod shelf 12 and then moving an empty pod from the pod shelf 12 to that wafer loading port. The process “A” of transferring a first empty wafer to one of the wafer loading ports is controlled in such a manner that the wafer transferring from the boat to the first empty pod can be conducted immediately after completing the opening of the door of the first pod.
The sequence shown in
Following advantages can be achieved in accordance with the present invention.
In contrast, the pod openers 20 in accordance with the present invention solely operate along horizontal directions and do not contribute at all to the height increase of the equipment and the pod-transfer time. Further, the pod shelf is arranged to receive two columns of pods along the width direction of the processing equipment, whereas only one column of wafer transferring ports is provided under the pod shelf. As a result, the purely transitional lateral motion of the pod openers can be accommodated by the reserved space under the pod shelf and, therefore, the system efficiency and the throughput can be improved without increasing the pod transfer time and sacrificing the floor area of the processing equipment.
It is to be appreciated that the configuration of the semiconductor processing equipment may be varied appropriately if necessary.
For instance, the number of the wafer loading ports is not limited to two but more than two wafer loading ports can be installed vertically of if the height increase can be accommodated.
In addition, in lieu of the rotary actuator for actuating the mapping device, another mechanism using an X-Y axis robot can be employed. Moreover, the mapping device can be omitted if so required.
Furthermore, the processing equipment can be of the type capable of processing other substrates, e.g., photo masks, printed circuit boards, liquid crystal panels, compact disks and magnetic disk, than the semiconductor wafers.
The processing equipment can be of the type adapted to perform, e.g., oxide formation, diffusion process and other types of heat treating process in place of the CVD. The present invention is also applicable to other types of semiconductor processing equipments than the batch type vertical processor.
While the invention has been shown and described with respect to the preferred embodiments, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims.
Matsunaga, Tatsuhisa, Nakashima, Takanobu, Yanagawa, Hidehiro
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