Abstract:
Methods, apparatus, and assemblies are provided for an adapter insert including an adapter frame including a support rail adapted to support one or more substrates in a substrate carrier, a frame extension coupled to, or integral with, the adapter frame, and a mapping feature formed on the frame extension and disposed to be detected by a sensor for determining whether an adapter insert is present or absent in a substrate carrier. Numerous additional features are disclosed.

Description:
RELATED APPLICATION 
       [0001]    The present application claims priority from U.S. Provisional Patent Application Ser. No. 61/847,732, filed Jul. 18, 2013, entitled “CARRIER ADAPTER INSERT APPARATUS AND CARRIER ADAPTER INSERT DETECTION METHODS” (Attorney Docket No. 20919/USAL/FEG/SYNX/CROC) which is hereby incorporated herein by reference in its entirety for all purposes. 
     
    
     BACKGROUND 
       [0002]    In some electronic device manufacturing facilities, larger size substrates (e.g., 450 mm) may be used to develop electronic devices. Thus, such facilities may be equipped with substrate carriers (e.g., front opening unified pods, also known as FOUPS) adapted to hold these larger size substrates. However, such facilities may also develop devices using smaller size substrates (e.g., 300 mm) and thus, carriers suitable for holding and transporting the smaller size substrates may be employed. However, tools and transport systems adapted to accommodate two or more sizes of substrate carriers can be expensive, redundant, and add undesired complexity and equipment to the manufacturing facility. Thus, conventional adapter inserts  100  as depicted in  FIG. 1  have been developed to allow, for example, carriers designed to hold larger 450 mm substrates to be adapted to hold smaller 300 mm substrates. 
         [0003]    Such conventional adapter inserts  100  can include a top frame portion  102 , a bottom frame portion  104  and two or more support rails  106 ,  108  extending between the top frame portion  102  and the bottom frame portion  104 . The support rails  106 ,  108  include slots that receive and support smaller size substrates (e.g., 300 mm substrates) therein. The top frame portion  102  and the bottom frame portion  104  are sized and positioned to fit within slots of a larger size (e.g., 450 mm) substrate carrier at locations where two larger size substrates would ordinarily be held. 
         [0004]    Even though the conventional adapter inserts  100  allow larger size carriers to safely and securely hold smaller size substrates, such conventional adapter inserts  100  may still require the robots and transfer systems of the manufacturing facility to be specially adapted to accommodate both substrate carriers with conventional adapter inserts  100  and carriers without such adapters, which can be expensive and add undesired complexity to the manufacturing facility. Thus, what is needed are improved adapter inserts and methods of detecting installed adapter inserts that do not require complex and expensive adaptions of existing robots and transfer systems of existing manufacturing facilities. 
       SUMMARY 
       [0005]    Embodiments of the present invention provide systems, methods, and apparatus for an adapter insert. The adapter insert includes an adapter frame, a support rail coupled to the adapter frame and adapted to support one or more substrates, a frame extension adapted to be coupled to the adapter frame, and a mapping feature formed on the frame extension and disposed to be detected by a sensor for determining whether an adapter insert is present or absent in a substrate carrier. Numerous additional features are disclosed. 
         [0006]    In another embodiment, a substrate carrier adapter apparatus is provided. The substrate carrier adapter apparatus includes an adapter insert frame, and a mapping feature coupled to, or integral with, the adapter insert frame and disposed to be detected by a sensor for determining whether the substrate carrier adapter apparatus is present or absent in a substrate carrier. 
         [0007]    Some embodiments of the present disclosure include computer-implemented methods for loading/unloading a substrate carrier. Some methods include providing a substrate carrier for loading or unloading of substrates, and determining whether an adapter insert is present or absent based on detecting a mapping feature. Subsequently, mapping of any substrates within the carrier based on the determining may be carried out. 
         [0008]    In another embodiment, a substrate carrier assembly is provided. The substrate carrier assembly includes a substrate carrier, and an adapter insert received in the substrate carrier, the adapter insert including an adapter frame, a support rail coupled to the adapter frame and adapted to support one or more substrates, a frame extension coupled to the adapter frame, and a mapping feature formed on the frame extension and disposed to be detected by a sensor for determining whether an adapter insert is present or absent in the substrate carrier. 
         [0009]    Numerous other aspects and embodiments are provided. 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 
         [0010]      FIG. 1  depicts an adapter insert according to the prior art. 
           [0011]      FIG. 2  depicts a first example embodiment of an adapter insert in accordance with some embodiments. 
           [0012]      FIG. 3  depicts a second example embodiment of an adapter insert in accordance with some embodiments. 
           [0013]      FIG. 4  depicts a flowchart illustrating an example method in accordance with some embodiments. 
       
    
    
     DESCRIPTION 
       [0014]    The present invention provides systems, methods, and apparatus to allow substrate carriers designed to hold substrates of a first size to be adapted to hold substrates of a second size without requiring extensive adaptation of the robots and transfer systems of a manufacturing facility. By adding a mapping feature or flag to an adapter insert, the existing substrate mapping sensors on the robot&#39;s end effector are easily able to detect the presence of the adapter insert of the present invention within the substrate carrier. The mapping feature (e.g., flag or other suitable structure) can be mounted on any practicable part of the frame (e.g., upper and/or lower portion) or support rails of the adapter insert and in some embodiments, the mapping feature can be formed from a portion of a cross bar or extension that mounts on one or more portions of the frame and/or support rails. 
         [0015]    Turning now to  FIG. 2 , an example embodiment of an adapter insert  200  according to the present invention is illustrated. As seen in the drawing, the conventional adapter insert  100  is modified to include a mapping feature  110 . Existing end effectors  112  can include mapping sensors with a light signal generator and a light signal receiver. The end effector  112  may be moved past the mapping feature  110  and the presence of the adapter insert  200  within the substrate carrier may be determined by the light beam  114  (shown dotted) being broken by the mapping feature  110 . Detection of the mapping feature  110  may be carried out by any suitable sensor system, such as a sensor on an end effector or load port door or at another suitable location. 
         [0016]    Note that any suitably shaped mapping feature  110  may be used to form the novel adapter insert  200  according to embodiments of the present invention, such as a tab or contour extending from a front of the adapter insert  200 . Any practicable materials may be used to form the mapping feature  110  and the frame extension  116  that supports the mapping feature  110 . 
         [0017]    In the depicted embodiment, the mapping feature  110  is formed, or part of, a frame extension  116  that is coupled to or integral with the lower frame portion  104 . However, the mapping feature  110  may be disposed on, or part of, any portion of the adapter insert frame, such as the top frame portion  102 , or even disposed on, or part of, the support rails  106 ,  108 . Any suitably shaped feature may be used. In some embodiments, the mapping feature  110  may include vertically-spaced indicator portions that have predetermined spacing different than the spacing of substrates held in the adapter insert  200 . 
         [0018]      FIG. 3  depicts a second embodiment of a novel adapter insert  300  including a mapping feature  310  on the adapter insert frame, and, in particular, that extends from frame extension  316 . In the depicted embodiment, the mapping feature  310  is formed or part of a frame extension  316  that is coupled to or integral with the lower frame portion  104 . Note that the contoured shape of the mapping feature  310  corresponds to the curved shape of a substrate held in the adapter insert  300 . Thus, in this embodiment, detecting the adapter insert  300  using the mapping feature  310  is similar to detecting a substrate in a substrate carrier. Any practicable materials may be used to form the mapping feature  310  and the frame extension  316 , such as aluminum. 
         [0019]    Turning now to  FIG. 4 , methods of one or more embodiments of the present invention are described. Note that embodiments of the present invention may include a programmed computer system adapted to receive and store data from an end effector  112  or robotic system that supports the end effector  112 , or otherwise receive information from a mapping sensor. The computer system may include one or more processors for executing instructions or programs that implement the methods described herein. The computer system may include memory and persistent storage devices to store and manipulate the instructions and sensor data received from the analyte monitoring system. The computer system may also include communications facilities (e.g., wireless and/or wired) to enable transfer of data from the system to the computer. The computer system may include a display and/or output devices for identifying dropouts in the sensor data to a user. The computer system may include input devices and various other components (e.g., power supply, operating system, clock, etc.) that are typically found in a conventional computer system. In some embodiments, the computer system may be integral to the substrate handling system. For example, the computer system may be embodied as a handheld or portable receiver unit wirelessly communicates with the system. 
         [0020]    The various methods described herein for performing one or more processes also described herein may be embodied as computer programs (e.g., computer executable instructions and data structures) developed using an object oriented programming language that allows the modeling of complex systems with modular objects to create abstractions that are representative of real world, physical objects and their interrelationships. However, any practicable programming language and/or techniques may be used. The software for performing the inventive processes, which may be stored in a memory or storage device of the computer system described herein, may be developed by a person of ordinary skill in the art based upon the present disclosure and may include one or more computer program products. The computer program products may be stored on a computer readable medium such as a server memory, a computer network, the Internet, and/or a computer storage device. 
         [0021]      FIG. 4  depicts an example embodiment of a method of the present invention. The carrier handling and unloading/loading system is initially presented with a carrier for loading or unloading ( 402 ). Next, the sensor (e.g., on the end effector) is moved to a predefined position to check for the presence of a mapping feature that indicates the presence of an adapter insert ( 404 ). If an adapter insert is detected, the system may then map the substrate slots of the adapter insert, and if the adapter insert is not detected, the system may map the substrate slots of the substrate carrier ( 406 ). 
         [0022]    Various other modifications and alterations in the structure and method of operation of the embodiments of the present disclosure will be apparent to those skilled in the art without departing from the scope of the present disclosure. Although the present disclosure has been described in connection with certain embodiments, it should be understood that the claims should not be unduly limited to such embodiments. It is intended that the following claims define the scope of the present disclosure and that structures and methods within the scope of these claims and their equivalents be covered thereby.