Abstract:
The present invention provides systems, methods, and apparatus for use with a substrate carrier. The invention provides a door opener adapted to employ a vacuum source to collapse an inflatable seal of a door of the substrate carrier. By collapsing the inflatable seal, the door is released from the body of the substrate carrier so that substrates may be removed and/or inserted into the carrier. A second vacuum source may be applied to the door to hold it securely to the door opener. Numerous other aspects of the invention are disclosed.

Description:
RELATED APPLICATIONS  
       [0001]     The present application claims priority to U.S. Provisional Patent Application Ser. No. 60/738,542, filed on Nov. 21, 2005 and entitled “APPARATUS AND METHODS FOR A SUBSTRATE CARRIER HAVING AN INFLATABLE SEAL,” which is hereby incorporated by reference herein for all purposes. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to electronic device manufacturing and, more particularly, to apparatus and methods related to sealing substrate carrier doors.  
       BACKGROUND  
       [0003]     It is generally preferable to protect substrates (e.g., patterned or unpatterned semiconductor wafers, glass panels, polymer substrates, reticules, masks, glass plates or the like) from exposure to any potential contaminating particles. Thus, such substrates may be stored in air tight containers. However, the substrates must typically be transported to different process tools within an electronic device manufacturing facility. Thus, what is needed are methods and apparatus for transporting substrates in sealed containers as well as systems and methods for accessing the substrates without exposing the substrates to potential contaminating particles.  
       SUMMARY OF THE INVENTION  
       [0004]     In a some aspects, the present invention provides an apparatus for use with a substrate carrier that includes a door opener adapted to employ a first vacuum source to collapse an inflatable seal of a door of a substrate carrier in order to release the door from a body of the substrate carrier.  
         [0005]     In other aspects of the present invention, a system for sealing substrate carriers is provided that includes a substrate carrier adapted to hold one or more substrates, and a loadport for receiving a substrate carrier from a substrate carrier transport system. The loadport includes a door opener adapted to employ a first vacuum source to collapse an inflatable seal of a door of a substrate carrier in order to release the door from a body of the substrate carrier.  
         [0006]     In yet other aspects of the present invention, a method is provided including receiving a substrate carrier at a loadport; mating a door opener to a door of the substrate carrier; applying a first vacuum pressure to the door via the door opener to hold the door; and applying a second vacuum pressure to an inflatable seal to collapse the inflatable seal and release the door of the substrate from the substrate carrier.  
         [0007]     Other features and aspects of the present invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]      FIG. 1  illustrates a perspective view of an exemplary embodiment of the apparatus of the present invention.  
         [0009]      FIG. 2  illustrates the apparatus of  FIG. 1  with the seal plate of the door opener body removed.  
         [0010]      FIG. 3  illustrates the apparatus of  FIG. 1  in a reverse perspective view showing the reverse sides of the substrate carrier door and the door opener body.  
         [0011]      FIG. 4  illustrates a side view of the components of the apparatus of  FIG. 3 , taken along line  4 - 4  in  FIG. 3 .  
         [0012]      FIG. 5  illustrates the side view of the apparatus of  FIG. 4  showing the door opener body attached to, or mated with, the substrate carrier door.  
         [0013]      FIG. 6  illustrates a cross sectional side view of the components of the apparatus of  FIG. 3  taken along line  6 - 6  in  FIG. 3 .  
         [0014]      FIG. 7  illustrates the side view of the apparatus of  FIG. 6  showing the door opener body attached to, or mated with, the FOUP door.  
         [0015]      FIG. 8  illustrates a system that employs the inventive FOUP door and door opener body of FIGS.  1  to  7 .  
         [0016]      FIG. 9  illustrates a flowchart that depicts an example process according to an embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0017]     The present invention relates to a substrate carrier door having an inflatable seal. For convenience, the invention is described in connection with a front opening unified pod (FOUP) door. However, it will be understood that the invention may be employed with any substrate carrier adapted to house and transport substrates such as semiconductor wafers, glass substrates, polymer substrates, masks, reticules and/or the like.  
         [0018]      FIG. 1  illustrates a perspective view of an exemplary embodiment of the apparatus of the present invention which is designated generally by the reference numeral  100 . With reference to  FIG. 1 , the apparatus  100  includes a FOUP door  200 . The FOUP door  200 , in an exemplary embodiment, may be used with, or in connection with, any suitable front opening unified pod (FOUP) (an example of which is depicted in  FIG. 8 ). The FOUP door  200  is adapted to seat into a door frame (not pictured) of a FOUP to create a sealed closure. The apparatus  100  also includes a door opener body  300  which is utilized with, or in connection with, a FOUP door opener ( FIG. 8 ) and/or loadport ( FIG. 8 ).  
         [0019]     With reference to  FIG. 1 , the FOUP door  200  includes an outer plate  210 , and an inner structure  220 , attached to the outer plate  210 . The outer plate  210  and the inner structure  220  may be attached to each other in any suitable manner such as via screws, bolts, etc., or may be integrally formed and/or of unitary construction.  
         [0020]     The FOUP door  200  also includes an inflatable door seal  230  which extends along and about the periphery of the outer plate  210 /inner structure  220  combination, as shown. In an exemplary embodiment, the inflatable door seal  230  can be made from rubber or a similar material (e.g., an elastic, flexible, and/or conforming material). When the FOUP door  200  is seated into the door frame of a FOUP, the inflatable door seal  230  may be inflated to press against the door frame and seal the FOUP closed.  
         [0021]     The FOUP door  200  may also include sockets  240  in the outer plate  210 , as shown, which may receive pins or other features of the door opener body  300  as will be described herein. In an exemplary embodiment, the sockets  240  may be registration pin sockets or similar kinematic features. Any number of sockets  240  can be utilized depending upon the design of the door opener body  300  and/or the FOUP door  200 . The FOUP door  200  also includes a door seal vacuum fitting  250  located in the outer plate  210 , as shown. Other fitting locations may be used.  
         [0022]     The outer plate  210  and inner structure  220  are adapted so that the outer plate  210  inner structure  220  combination allows air or any other gas to pass out of the inflatable door seal  230  via the door seal vacuum fitting  250  and allows air or any other gas to pass from the door seal vacuum fitting  250  into the inflatable door seal  230 . In this manner, an application of a vacuum to the door seal vacuum fitting  250  can deflate or collapse the door seal  230 . The removal of the vacuum from the door seal vacuum fitting  250  (and/or application of pressurized air gas) may allow air or any other gas (which in some embodiments may be applied to the door seal vacuum fitting  250 ) to enter through the door seal vacuum fitting  250  in order to re-inflate or expand the door seal  230 .  
         [0023]     With reference once again to  FIG. 1 , the door opener body  300  includes an outer wall  310  and an inner wall  320 . The inner wall  320  is adapted to face the outer plate  210  of the FOUP door  200 . The door opener body  300  also includes a seal plate  330  which is removeably attached to the outer wall  310  of the door opener body and which serves as a cover for an interior region of the door opener body  300 .  
         [0024]     The door opener body  300  further includes a door retention port  340  which can be connected to a vacuum source (not shown) for allowing vacuum retention of the FOUP door  200  via the door opener body  300  as will be described in more detail herein. The door opener body  300  also includes a door seal activation port  350  which can be connected to a vacuum source (not shown) for vacuum activation (deflation) of the door seal  230  of the FOUP door  200  (as will be described below).  
         [0025]     In an exemplary embodiment, the apparatus and methods of the present invention may utilize two vacuum sources, any number of vacuum sources, or a single vacuum source adapted to provide the functionality of the vacuum sources described herein. Alternatively or additionally, the present invention may use one or more air or gas sources to inflate the door seal  230  of the FOUP door  200 .  
         [0026]      FIG. 2  illustrates the apparatus  100  of  FIG. 1  with the seal plate  330  of the door opener body  300  removed. With the seal plate  330  removed, the inner region  360  of the door opener body  300  is exposed. Within the inner region  360 , the door opener body  300  may include a door retention vacuum channel  370 . The door retention vacuum channel  370  is connected to the door retention port  340  via a channel  341  so as to provide a vacuum, when vacuum pressure is applied from a respective vacuum source, for holding the FOUP door  200  in place against the door opener body  300  as will be described in more detail herein.  
         [0027]     Within the inner region  360 , the door opener body  300  may include a door seal activation vacuum channel  380 . The door seal activation vacuum channel  380  is connected to the door seal activation port  350  via a channel  351  so as to allow a vacuum to be applied from a respective vacuum source to collapse the door seal  230  as will be described in more detail herein.  
         [0028]      FIG. 3  illustrates the apparatus  100  of  FIG. 1  in a reverse perspective view showing the reverse sides of the FOUP door  200  and the door opener body  300 . With reference to  FIG. 3 , the door opener body  300  includes, on its inner wall  320 , a door seal vacuum fitting  355  which, in an exemplary embodiment, is adapted to extend into the door seal vacuum fitting  250  of the FOUP door  200 . The door seal vacuum fitting  355  is connected to the door seal activation vacuum channel  380  ( FIG. 2 ). The door opener body  300  may also include, on the inner wall  320 , pins  345  or other registration/kinematic features which, in an exemplary embodiment, are adapted to kinematically mate with the sockets  240  ( FIG. 2 ) of the FOUP door  200 . Any number and practicable shape of pins  345  may be used depending upon the design of the door opener body  300  and/or the FOUP door  200 .  
         [0029]     With reference once again to  FIG. 3 , the door opener body  300  may also include, on the inner wall  320 , door retention vacuum cups or elements  375 . In the embodiment shown, two door retention vacuum cups  375 , are utilized in order to hold the FOUP door  200  against the door opener body  300 . In general, any number of door retention vacuum cups  375  may be used (e.g., 1, 2, 3, 4, etc.).  
         [0030]     The door retention vacuum cups  375  may be made of any suitable material capable of forming a seal against the FOUP door  200 , such as polytetrafluoroethylene (PTFE) or the like. In one embodiment, each door retention vacuum cup  375  may be formed by machining a channel (not shown) in the inner wall  320  of the door opener body  300  and by placing an O-ring  377  or similar sealing element within the channel. The door retention vacuum cups  375  are connected with the door retention vacuum channel  370  ( FIG. 2 ) and can hold the FOUP door  200  against the door opener body  300  when a vacuum is applied from a respective vacuum source and provided to the door retention vacuum cups  375  via the door retention port  340  ( FIG. 2 ) and the door retention vacuum channel  370  ( FIG. 2 ).  
         [0031]      FIG. 4  illustrates a side view of the components of the apparatus  100  of  FIG. 3 , taken along line  4 - 4  in  FIG. 3 . In  FIG. 4 , the FOUP door  200  and the door opener body  300  are shown spaced apart from one another.  FIG. 4  illustrates the outer plate  210 , the inner structure  220 , and the inflatable seal  230  of the FOUP door  200 .  FIG. 4  also illustrates the outer wall  310 , the inner wall  320 , the pins  345  and the door retention vacuum cups  375  of the door opener body  300 .  
         [0032]      FIG. 5  illustrates a side view of the apparatus  100  of  FIG. 4  now showing the door opener body  300  attached to, and/or mated with, the FOUP door  200 . In other words, inner wall  320  of the door opener body  300  is in contact with the outer plate  210  of the FOUP door  200  and the pins  345  ( FIG. 3 ) of the door opener body  300  are mated into the sockets  240  ( FIG. 2 ) in the outer plate  210 . In the depicted configuration, if vacuum pressure is applied to the door retention vacuum cups  375  via the door retention vacuum channel  370  ( FIG. 2 ) via the door retention port  340  ( FIG. 2 ), the FOUP door  200  may be held against the door opener body  300 .  
         [0033]      FIG. 6  illustrates a cross sectional side view of the components of the apparatus  100  of  FIG. 3  taken along line  6 - 6  in  FIG. 3 . In  FIG. 6 , the FOUP door  200  and the door opener body  300  are shown spaced apart from one another.  
         [0034]      FIG. 6  illustrates the door opener body  300  and the outer wall  310 , the inner wall  320 , the seal plate  330 , the door retention vacuum channel  370 , the door seal activation vacuum channel  380 , the connecting channel  351 , the door seal vacuum fitting  355 , the pin  345 , and the door retention vacuum cup  375 .  FIG. 6  also illustrates the FOUP door  200  and the outer plate  210 , the inner structure  220 , the inflatable seal  230  and the door seal vacuum fitting  250 . The door seal vacuum fitting  250  may include a sealing element  610  (e.g., an O-ring) for forming a seal between the door seal vacuum fitting  250  and the door seal vacuum fitting  355  (as shown in  FIG. 7 ).  
         [0035]     Turning now to  FIG. 7 , a cross sectional side view of the apparatus  100  of  FIG. 6  is illustrated that depicts the door opener body  300  attached to, or mated with, the FOUP door  200 . In other words, inner wall  320  of the door opener body  300  is in contact with the outer plate  210  of the FOUP door  200  and the pins  345  ( FIG. 3 ) of the door opener body  300  are mated into the sockets  240  ( FIG. 2 ) in the outer plate  210 . In the depicted configuration, if vacuum pressure is applied to the door retention vacuum cups  375  via the door retention vacuum channel  370  ( FIG. 2 ) via the door retention port  340  ( FIG. 2 ), the FOUP door  200  may be held against the door opener body  300 .  
         [0036]      FIG. 8  illustrates a system  800  that employs the inventive FOUP door  200  and door opener body  300  of  FIGS. 1-7 . With reference to  FIG. 8 , the system  800  includes a substrate carrier  810  (e.g., a FOUP) having the FOUP door  200  coupled thereto. That is, the door  200  is positioned within an opening  815  of the substrate carrier  810  and the inflatable seal  230  (not shown in  FIG. 8 ) is inflated to hold the door  200  therein.  
         [0037]     The system  800  also includes a loadport  820  having a door opener  825  coupled thereto. The door opener  825  includes the door opener body  300  (not shown in  FIG. 8 ). A first vacuum source  830  may be coupled to the door opener body  300  via a first vacuum line  832  for applying a first vacuum to door retention vacuum cups  375  of the door opener body  300 . Likewise, a second vacuum source  835  may be coupled to the door opener body  300  via a second vacuum line  834  for applying a second vacuum to the door seal  230  of the door  200 . The first and second vacuum sources  830 ,  835  may be supplied from a single vacuum source or multiple vacuum sources (e.g., one or more vacuum pumps).  
         [0038]     The system  800  may also include a controller  840  that is adapted to control the system  800 . The controller  840  may be connected to the loadport  820  via a signal cable and may direct the operation of the robot and door opener  825 . The controller  840  may also be directly coupled to the vacuum sources  830 ,  835  and be further adapted to directly control the vacuum sources  830 ,  835  to execute the methods of the present invention, for example, as described below with respect to  FIG. 9 .  
         [0039]     Turning now to  FIG. 9 , an exemplary method  900  of the present invention is described with respect to the system depicted in  FIG. 8 . In Step  902 , when an opening operation is to be performed on the FOUP door  200 , the FOUP  810  may be positioned at the loadport  820  by a robot (not shown). In Step  904 , the FOUP may thereafter be moved toward the door opener  825  of the loadport  820  so that the FOUP door  200  contacts the door opener body  300  (as shown, for example, in  FIGS. 5 and 7 ).  
         [0040]     When the FOUP door  200  is moved into contact with, and/or against, the door opener body  300 , the pins  345  of the door opener body  300  engage and/or mate with the sockets  240  on the outer plate  210  of the FOUP door  200  (see  FIGS. 4-5 ). The FOUP door  200  continues to be moved toward the door opener body  300  until the outer plate  210  is moved into contact with the door retention vacuum cups  375  ( FIG. 5 ), and the door seal vacuum fitting  355  is also moved into the door seal vacuum fitting  250  ( FIGS. 6-7 ).  
         [0041]     In Step  906 , a first vacuum may be applied from the first vacuum source  830  to the door retention port  340  and to the door retention vacuum cups  375  via the door retention vacuum channel  370 . Upon the application of the first vacuum, the outer plate  210  of the FOUP door  200  is pulled tightly against the door opener body  300 .  
         [0042]     The first vacuum may then be verified so as to ensure that the FOUP door  200  is held against the door opener body  300 . In this manner, the first vacuum may be used to allow the door opener body  300  to grab onto or attach itself to the FOUP door  200  and, thereafter, to hold and/or secure the FOUP door  200  in place during a subsequent door opening and/or closing operation (described below) or to otherwise manipulate the FOUP door  200 .  
         [0043]     Once the FOUP door  200  is attached to and held by the door opener body  300 , in Step  908 , a second vacuum is applied from the second vacuum source  835  to the door seal activation port  350  and to the door seal vacuum fitting  355  via door seal activation vacuum channel  380 . The second vacuum is applied to the door seal  230  via the door seal vacuum fitting  250 . The application of the second vacuum to the door seal vacuum fitting  250  causes the door seal  230  to become deflated and/or collapsed. Thereafter, in Step  910 , the FOUP door  200  may be removed from the opening  815  of the FOUP  810 , thereby opening the FOUP  810 . Once open, in Steps  912  and  914 , substrates may be added and/or removed from the FOUP  810 .  
         [0044]     To close the FOUP door  200 , the above process may be performed in reverse. For example, in an exemplary embodiment, the FOUP door  200  may be moved to the closed position so as to close the front opening  815  of the FOUP  810  in Step  916 . In Step  918 , the second vacuum source  835  may be disconnected in order to allow the door seal  230  to re-inflate or expand, thereby sealing the FOUP door  200  closed. (If desired, a source of air, nitrogen or another gas, not separately shown, may be employed to inflate the door seal  230 .) Thereafter, in Step  920 , the first vacuum source  830  may be disconnected so as to release the door retention vacuum cups  375  from the outer plate  210  of the FOUP door  200 . The FOUP  810  may then be moved or transported away from the door opener body  300  and away from the door opener  825  in Step  922 .  
         [0045]     In the exemplary embodiment described above, the apparatus  100  is described as utilizing two vacuum sources. The first vacuum source  830  may serve to allow the door opener body  300  to grab onto or attach itself to the FOUP door  200 . The second vacuum source  835  may cause the door seal  230  to deflate or collapse to allow opening of the FOUP door  200  after control of the FOUP door  200  has been established by the first vacuum source  835 . In another exemplary embodiment, any number of vacuum sources may be used. In still another exemplary embodiment, a single vacuum source, adapted to perform both of the above operations, may be utilized.  
         [0046]     While the present invention has been described and illustrated in various exemplary embodiments, such descriptions are merely illustrative of the present invention and are not to be construed to be limitations thereof. In this regard, the present invention encompasses any and all modifications, variations and/or alternate embodiments with the scope of the present invention being limited only by the claims which follow.