Abstract:
The invention provides methods, systems and apparatus for opening a substrate carrier. The invention provides a novel loadport for receiving a substrate carrier from a substrate carrier transport system. The loadport includes a door opening mechanism adapted use vacuum pressure to hold a substrate carrier door against the door opening mechanism. The loadport is further adapted to apply a gas flow to the periphery of the substrate carrier to block potential contaminants from entering the substrate carrier. Numerous other features are provided.

Description:
[0001]    The present application claims priority to U.S. Provisional Patent Application Ser. No. 60/751,085, filed Dec. 16, 2005 and titled “SMALL LOT SIZE SUBSTRATE CARRIERS” (Attorney Docket No. 9604/L/SYNX/SYNX), which is hereby incorporated by reference herein in its entirety. 
       RELATED APPLICATIONS 
       [0002]    The present application is related to the following commonly-assigned United States Patent Applications, each of which is hereby incorporated by reference herein in its entirety: 
         [0000]    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” (Attorney Docket No. 9611);
 
U.S. Provisional Patent Application Ser. No. 60/542,519, filed Feb. 5, 2004 and titled “SMALL LOT SIZE SUBSTRATE CARRIERS” (Attorney Docket No. 8827/L2/JB);
 
U.S. patent application Ser. No. 10/764,820, filed Jan. 26, 2004 and titled “OVERHEAD TRANSFER FLANGE AND SUPPORT FOR SUSPENDING A SUBSTRATE CARRIER” (Attorney Docket No. 8092);
 
U.S. provisional application Ser. No. 60/443,153, filed Jan. 27, 2003 and titled “OVERHEAD TRANSFER FLANGE AND SUPPORT FOR SUSPENDING WAFER CARRIER” (Attorney Docket No. 8092/L);
 
U.S. patent application Ser. No. 10/650,310, filed Aug. 28, 2003 and titled “System For Transporting Substrate Carriers” (Attorney Docket No. 6900);
 
U.S. patent application Ser. No. 10/650,312, filed Aug. 28, 2003 and titled “Method and Apparatus for Using Substrate Carrier Movement to Actuate Substrate Carrier Door Opening/Closing” (Attorney Docket No. 6976);
 
U.S. patent application Ser. No. 10/650,481, filed Aug. 28, 2003 and titled “Method and Apparatus for Unloading Substrate Carriers from Substrate Carrier Transport Systems” (Attorney Docket No. 7024);
 
U.S. patent application Ser. No. 10/650,479, filed Aug. 28, 2003 and titled “Method and Apparatus for Supplying Substrates to a Processing Tool” (Attorney Docket No. 7096);
 
U.S. Patent Application Ser. No. 60/407,452, filed Aug. 31, 2002 and titled “End Effector Having Mechanism For Reorienting A Wafer Carrier Between Vertical And Horizontal Orientations” (Attorney Docket No. 7097/L);
 
U.S. Patent Application Ser. No. 60/407,337, filed Aug. 31, 2002, and titled “Wafer Loading Station with Docking Grippers at Docking Stations” (Attorney Docket No. 7099/L);
 
U.S. patent application Ser. No. 10/650,311, filed Aug. 28, 2003 and titled “Substrate Carrier Door having Door Latching and Substrate Clamping Mechanism” (Attorney Docket No. 7156);
 
U.S. patent application Ser. No. 10/650,480, filed Aug. 28, 2003 and titled “Substrate Carrier Handler That Unloads Substrate Carriers Directly From a Moving Conveyor” (Attorney Docket No. 7676);
 
U.S. Provisional Application Ser. No. 60/443,087, filed Jan. 27, 2003 and titled “Methods and Apparatus for Transporting Wafer Carriers” (Attorney Docket No. 7163/L);
 
U.S. Provisional Application Ser. No. 60/443,001, filed Jan. 27, 2003, and titled “Systems and Methods for Transporting Wafer Carriers Between Processing Tools” (Attorney Docket No. 8201/L); and
 
U.S. Provisional Application Ser. No. 60/443,115, filed Jan. 27, 2003, and titled “Apparatus and Method for Storing and Loading Wafer Carriers” (Attorney Docket No. 8202/L).
 
     
    
     FIELD OF THE INVENTION 
       [0003]    The present invention relates to electronic device manufacturing and, more particularly, to apparatus and methods related to opening and closing substrate carrier doors. 
       BACKGROUND 
       [0004]    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 
       [0005]    In a some aspects, the present invention provides a system for opening a substrate carrier 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, wherein the loadport includes a door opening mechanism, the door opening mechanism adapted use vacuum pressure to hold a substrate carrier door against the door opening mechanism. 
         [0006]    In some other aspects, the present invention provides a method that includes receiving a substrate carrier at a loadport; aligning a door opener of the loadport with a door of the substrate carrier; and applying a vacuum pressure to the door via the door opener to hold the door. 
         [0007]    In yet other aspects of the present invention, an apparatus for use with a substrate carrier is provided that includes a loadport including a door opening mechanism, wherein the door opening mechanism is adapted use vacuum pressure to hold a substrate carrier door against the door opening mechanism. 
         [0008]    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 
         [0009]      FIG. 1  is an exemplary embodiment of a substrate carrier having an overhead transfer flange and that is adapted to transport a single substrate; 
           [0010]      FIGS. 2A-L  illustrate a first exemplary embodiment of a door opening mechanism for opening the door of a substrate carrier; 
           [0011]      FIGS. 3A-L  illustrate a second exemplary embodiment of a door opening mechanism for opening the door of a substrate carrier; 
           [0012]      FIGS. 4A-B  illustrate a third exemplary embodiment of a door opening mechanism for opening the door of a substrate carrier; 
           [0013]      FIGS. 5A-E  illustrate a fourth exemplary embodiment of a door opening mechanism for opening the door of a substrate carrier; 
           [0014]      FIGS. 6A-G  illustrate various components of an exemplary substrate carrier; 
           [0015]      FIGS. 7A-E  illustrate an apparatus for storing a plurality of substrate carriers in accordance with an embodiment of the present invention; 
           [0016]      FIGS. 8A-C  illustrate an exemplary door for sealing a substrate carrier in accordance with an embodiment of the present invention; 
           [0017]      FIGS. 9A-B  illustrate isometric views of a front of a door opening mechanism in accordance with an embodiment of the present invention; 
           [0018]      FIGS. 10A-B  illustrate isometric views of a rear of the door opening mechanism in accordance with an embodiment of the present invention; 
           [0019]      FIG. 11  is a cross-sectional side view of the door opening mechanism in accordance with an embodiment of the present invention; and 
           [0020]      FIG. 12  is a cross-sectional side view of the door opening mechanism coupled to the door for sealing a substrate carrier in accordance with an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    The present invention provides a door opening mechanism that employs a vacuum for unlatching a substrate carrier door from remaining portions of the substrate carrier and/or for coupling the door opening mechanism to the door while opening the door. In some embodiments the periphery of the substrate carrier may be flushed with clean dry air or other non-contaminating gas (e.g., N 2 ) when the substrate carrier is opened in a loadport employing the door opening mechanism. 
         [0022]    The figures and the following description thereof provide a specific configuration that embodies the inventive aspects identified above. Thus, the particular configuration of  FIGS. 1-12 , is merely exemplary and it will be understood that alternative configurations may be designed that function in accordance with the invention. 
         [0023]      FIG. 1  is an exemplary embodiment of a substrate carrier  201   a  with an overhead transfer flange  113   a  and that is adapted to transport a single substrate. The present invention is applicable to substrate carriers that are adapted to hold two or more substrates as well. The substrate carrier  201   a  includes a door  203  that may be removed to allow access to a substrate stored within the substrate carrier  201   a  (as described further below). In the exemplary embodiment shown, the door  203  may include latches  205   a,b  that allow the door  203  to be selectively secured to and removed from the remainder of the substrate carrier  201   a . The door  203  may include a region  207 , such as a metallic or otherwise magnetic permeable region (e.g., iron, stainless steel, etc.), that allows the door  203  to be held securely by a door opening mechanism (described below) when access to an interior of the substrate carrier  201   a  is desired (e.g., for removing a substrate from or loading a substrate into the substrate carrier  201   a ). The remainder of the substrate carrier  201   a  may be fabricated from polycarbonate, Victrex® PEEK or another suitable material. Note that the height of a substrate carrier may be increased as the substrate capacity of the substrate carrier is increased. 
         [0024]      FIGS. 2A-L  illustrate a first exemplary embodiment of a door opening mechanism  209  for opening the door  203  of the substrate carrier  201   a . With reference to  FIGS. 2A-L , the substrate carrier  201   a  is supported at a loadport location  211  using the blade receivers  121   a ,  121   b  and the overhead transfer flange  113   a  (e.g., allowing substrate carriers to be stacked with a high packing density). The door opening mechanism  209  includes a supporting member  213  that is adapted to contact and support the door  203  of the substrate carrier  201   a , and pivot the door  203  below the remainder of the substrate carrier  201   a  (e.g., into a housing  215 ) as described further below. A linear actuator or other actuator  217  (e.g., a pneumatic, motor driven, etc., actuator) may be employed to dock/undock the substrate carrier relative to the door opening mechanism  209  and/or a loadport  219  of the loadport location  211 . 
         [0025]    In operation, the substrate carrier  201   a  is supported at the loadport location  211  by the blades  121   a ,  121   b  (via the overhead transfer flange  113   a  of the substrate carrier  201   a ) as shown in  FIGS. 2A and 2B . The door  203  of the substrate carrier  201   a  is then moved toward and brought into contact with the supporting member  213  via the actuator  217  ( FIGS. 2C-D ). As will be described further below, the supporting member  213  may unlatch and support the door  203  in response to such docking motion. 
         [0026]    Following unlatching of the door  203 , the substrate carrier  201   a  is moved away from the loadport  219 , leaving the door  203  supported by the supporting member  213  ( FIGS. 2E-F ). The supporting member  213  then is lowered (e.g., via an actuating mechanism not shown) into the housing  215  ( FIGS. 2G-J ). In this position, the door  203  is positioned below the substrate carrier  201   a , and in the embodiment shown, in a substantially horizontal plane. Such an embodiment reduces the amount of space required to accommodate the door  203  (e.g., allowing closer loadport stacking). Once the door has been lowered, the substrate carrier  201   b  may be re-docked with the loadport  219  (e.g., to allow a substrate  221  to be removed therefrom) as shown in  FIGS. 2K-L . Note that in the above configuration, the supporting member  213  is positioned above the door  203  and may protect the door  203  from being contaminated by particles generated during docking or undocking of the substrate carrier  201   a . The supporting member  213  may be formed from any suitable material (e.g., a metal such as aluminum or the like). 
         [0027]      FIGS. 3A-L  illustrate a second exemplary embodiment of a door opening mechanism  209 ′ for opening the door  203  of the substrate carrier  201   a . With reference to  FIGS. 3A-L , the substrate carrier  201   a  is supported at a loadport location  211  using the blade receivers  121   a ,  121   b  and the overhead transfer flange  113   a  (e.g., allowing substrate carriers to be stacked with a high packing density). The door opening mechanism  209 ′ includes a supporting member  213  that is adapted to contact and support the door  203  of the substrate carrier  201   a , and pivot the door  203  below the remainder of the substrate carrier  201   a  as described further below. A linear actuator or other actuator  217  (e.g., a pneumatic, motor driven, hydraulic, etc., actuator) may be employed to dock/undock the substrate carrier relative to the door opening mechanism  209  and/or a loadport  219  of the loadport location  211 . The door opening mechanism  209 ′ of  FIGS. 3A-L  operates similarly to the door opening mechanism  209  of  FIGS. 2A-L , except that the door  203  faces toward the substrate carrier  201   a  when the supporting member  213  is pivoted downward as shown in  FIGS. 3G-L . In such a configuration, the door  203  may be exposed to particles generated during docking/undocking of the substrate carrier  201   a.    
         [0028]      FIGS. 4A-B  illustrate a third exemplary embodiment of a door opening mechanism  209 ″ for opening the door  203  of the substrate carrier  201   a . With reference to  FIGS. 4A-B , the door opening mechanism  209 ″ includes a supporting member (not shown) for unlatching and supporting the door  203  (not visible in  FIGS. 4A-B ) of the substrate carrier  201   a  (in a manner similar to that described with reference to  FIGS. 2A-L  and  FIGS. 3A-L ). However, the door opening mechanism  209 ″ includes a rotation device  401  (e.g., a motor) adapted to rotate the door  203  about a central axis of the door  203  (and/or about a central axis of the supporting member (not shown); and a linear actuator  403  which is adapted to lower the door (and/or supporting member) down below the substrate carrier  201   a . In this manner, the door  203  may be removed, rotated so as to be approximately horizontal and lowered below the substrate carrier  201   a . Note that the door  203  may be rotated after it is lowered via the linear actuator  403 . In at least one embodiment, the rotation device  401  may move up and/or down with the door  203 . 
         [0029]      FIGS. 5A-E  illustrate a fourth exemplary embodiment of a door opening mechanism  209 ′″ for opening the door  203  of the substrate carrier  201   a . With reference to  FIGS. 5A-E , the door opening mechanism  209 ′″ includes a supporting member  213  that is adapted to contact and support the door  203  of the substrate carrier  201   a , and pivot the door  203  below the remainder of the substrate carrier  201   a  as described further below. One or more sides of a loadport  211  may be provided with a channel  501  (only shown on one side) (e.g., a cam slot) adapted to accommodate one or more features  503  (only shown on one side) (e.g., cam followers) of the supporting member  213 . The channel  501  may be employed to lower and pivot the door  203  of the substrate carrier  201   a  of the remainder of the substrate carrier  201   a.    
         [0030]    In operation, a substrate carrier  201   a  is docked into contact with the supporting member  213 . In the embodiment shown, unlatching features  505  of the supporting member  213  engage latches of the substrate carrier  201   a  (described below) and unlatch the door  203 . Engaging features  507  (e.g., electromagnets in the embodiment shown) contact and hold the door  203  as the substrate carrier door  203  is moved away from the substrate carrier  201   a  ( FIG. 5A ). An actuating mechanism (not shown) then may lower the supporting member  213  and the door  203  below the substrate carrier  201   a  using the channel  505  and features  503  of the supporting member  213  ( FIG. 5B ). In at least one embodiment, a linkage  509  ( FIG. 5D ) may be employed to move the unlatching features  505  simultaneously. 
         [0031]      FIGS. 6A-G  illustrate various components of an exemplary substrate carrier  201   a . With reference to  FIGS. 6A-G , the substrate carrier  201   a  includes a top  601  and a bottom  603 . Front and back perspective views of the door  203  are shown in  FIGS. 6D-E , respectively. The door includes the latches  205   a,b  and region  207  described previously, as well as a substrate support member  605  ( FIG. 6E ) adapted to contact and support a substrate positioned within the substrate carrier  201   a  when the door is latched thereto. 
         [0032]      FIG. 6G  is an enlarged portion of the latch  205   b . As shown in  FIG. 6G , the latch  205   b  includes a rotary portion  607  that may be engaged and rotated by an unlatching mechanism of a substrate carrier door opener. First and second extensions  609   a ,  609   b  of the rotary portion  607  extend radially from the rotary portion and engage guide features  611   a ,  611   b  of the substrate carrier  201   a . The guide features  611   a ,  611   b  may latch (lock) the door  203  in position (e.g., when the extensions  609   a ,  609   b  are in the position illustrated in  FIG. 6G ). To unlatch the door, the rotary portion  607  may be rotated (clockwise in the embodiment of  FIG. 6G ) such that the extensions  609   a ,  609   b  disengage the guide features  611   a ,  611   b . In at least one embodiment, the rotary portion  607  may be rotated by about 90 degrees so that the extension  609   a ,  609   b  lie within an approximately horizontal plane. A retaining feature  613  may be provided that engages one of the extensions  609   a ,  609   b  so as to hold the rotary portion  607  in a known position. In such a position, the door  203  may be removed from the substrate carrier  201   a.    
         [0033]      FIGS. 7A-E  illustrate an apparatus  2401  for storing a plurality of substrate carriers in accordance with an embodiment of the present invention. With reference to  FIGS. 7A-E , the apparatus  2401  includes a plurality of loadports  2403 - 2407  in a stacked configuration adapted to dock or undock a plurality of substrate carriers  2409 - 2413 . The loadports  2403 - 2407  may be adapted to dock/undock substrate carriers that store a single substrate or a larger number of substrates. In at least one embodiment, the apparatus  2401  may be dimensioned such that a bottom substrate stored in the substrate carrier  2409  positioned at the lowest loadport  2403  corresponds to the lowest substrate in a 25-substrate substrate carrier and a top substrate stored in the substrate carrier positioned at the highest loadport  2407  corresponds to the highest substrate in a 25-substrate carrier. In this manner, the apparatus  2401  may store a plurality of substrate carriers  2409 - 2413  in the same space occupied by a conventional 25-substrate substrate carrier. Other loadport spacings may be employed. The structure of the loadports  2403 - 2407  is similar to the loadport  219  described above, and loadports  2403 - 2407  support substrate carriers  2409 - 2413  in a manner similar to that described above. 
         [0034]    Each of the loadports  2403 - 2407  includes a door opening mechanism  2415  for removing a substrate carrier door  2417  in accordance with an embodiment of the present invention. The apparatus  2401  includes a fitting  2419  corresponding to and/or coupled to each door opening mechanism  2415 . Each fitting  2419  is adapted to provide a vacuum to one of the door opening mechanisms  2415 . Further, the apparatus  2401  includes an actuator  2421  corresponding to and/or coupled to each door opening mechanism  2415 . Each actuator  2421  (such as a motor or similar actuator) is adapted to rotate a door opening mechanism  2415  as described further below (e.g., from a horizontal to a vertical position or vice versa). Details of the substrate carrier doors  2417  are described below with reference to  FIGS. 8A-C  and details of the door opening mechanisms  2415  are described below with reference to  FIGS. 9A-12 . 
         [0035]      FIGS. 7C-D  illustrate a side view and a cross-sectional side view, respectively, of the apparatus  2401  in accordance with an embodiment of the present invention. With reference to  FIGS. 7C-D , similar to the loadport  219  described above, each of the loadports  2403 - 2407  may include one or more blade receivers  2425  similar to the blade receivers  121   a - b  described above. Further, each of the substrate carriers  2409 - 2413  includes an overhead transfer flange  2427  similar to the overhead transfer flange  113   a  described above. In this manner, a blade receiver  2425  of a loadport  2403 - 2407  may support a substrate carrier  2409 - 2413  via an overhead transfer flange  2427 . An end effector  2429  may be employed to load the substrate carriers  2409 - 2413  onto (or unload the substrate carriers  2409 - 2413  from) the blade receivers  2425  of the loadports  2403 - 2407 . 
         [0036]      FIG. 7E  illustrates a rear view of the apparatus  2401  in accordance with an embodiment of the present invention. With reference to  FIG. 7E , the loadports  2403 - 2407  may be dimensioned such that when a substrate carrier  2409 - 2413  is stored in a loadport  2403 - 2407 , a space  2430  is provided between the substrate carrier  2409 - 2413  and the loadport  2403 - 2407  that substantially surrounds the substrate carrier  2409 - 2413 . In some embodiments, to maintain a clean environment around the substrate carriers  2409 - 2413 , clean air or another clean gas (e.g., nitrogen, argon, etc.), may be blown downward in front of the apparatus  2401 . In such embodiments, a high pressure-region may be created in front of the apparatus  2401 . Consequently, clean air may flow through each space  2430  from a front of the loadports  2403 - 2407  through a rear of the loadports  2403 - 2407 . In this manner, an outer surface of the substrate carrier  2409 - 2413  may be flushed by such air (or other gas). Particles or other contaminants thereby may be discouraged from entering the substrate carriers  2409 - 2413  (when the substrate carriers are opened) and/or a processing tool coupled to the apparatus  2401  and adapted to receive substrates therefrom. 
         [0037]      FIGS. 8A-C  illustrate an exemplary embodiment of the door  2417  of  FIG. 7A . With reference to  FIGS. 8A-C , the exemplary door  2417  for sealing a substrate carrier  2409 - 2413  includes one or more features  2431  (e.g., sockets, slots, etc.) adapted to couple to a corresponding registration feature of the door opening mechanism  2415  of a loadport  2403 - 2407 . The features  2431  may ensure proper alignment of the door  2417  with a door opening mechanism  2415  (e.g., via kinematic alignment between the features  2431  of the door  2417  and corresponding features  2603  of a door opening mechanism  2415  described below with reference to  FIGS. 9A-B ). In one embodiment, the features  2431  may be round or oval-shaped. However, the one or more features may be shaped differently. Although the door  2417  includes two features  2431 , a larger or smaller number of features  2431  may be employed. 
         [0038]    The door  2417  is adapted to receive vacuum pressure from a door opening mechanism  2415 , and in response to the vacuum pressure, release (e.g., unlatch or unlock) from a remaining portion of the substrate carrier  2409 - 2413  and/or couple (e.g., adhere) to the door opening mechanism  2415 . For example, the door  2417  (e.g., an outwardly facing side of the door  2417 ) may include one or more passageways  2433  for receiving the vacuum pressure. In some embodiments, the passageways  2433  may couple to a bladder (not shown) around a periphery of the door  2417  that is employed to secure or seal the door  2417  to the body of a substrate carrier  2409 - 2413 . In one particular embodiment, the door  2417  may not be removed from the substrate carrier  2409 - 2413  while the bladder is inflated and may be removed from the substrate carrier  2409 - 2413  only while the bladder is deflated. Alternatively, the passageways  2433  may lead to a different mechanism (e.g., a different vacuum actuated mechanism) for unlatching or unlocking the door  2417  from the body of a substrate carrier  2409 - 2413  or the passageway may simply lead towards a central plane A of the door  2417  ( FIG. 8C ) so as to allow the door  2417  to be held via vacuum by a door opening mechanism  2415 . 
         [0039]    The door  2417  includes a seal  2435  around (e.g., concentric to) each passageway  2433  for ensuring a vacuum remains in the passageway  2433 . A portion  2437  of each seal  2435  may extend from the door  2417 . Each seal  2435  may be formed from rubber, another elastomeric material, or any other suitable material. In some embodiments, the door  2417  may include the seals  2435  and thus, the seals  2435  may be more easily replaced than if the seals were present on the door opening mechanism  2415 . Nonetheless, one or more seals  2435  may be included in a door opening mechanism  2415 . 
         [0040]      FIGS. 9A-B  illustrate isometric views of a front of a door opening mechanism  2415  in accordance with an embodiment of the present invention. With reference to  FIGS. 9A-B , the door opening mechanism  2415  includes a bearing  2601  through which a shaft (not shown) that couples the door opening mechanism  2415  to the apparatus  2401  is inserted. The bearing  2601  enables the door opening mechanism  2415  to pivot with respect to the apparatus  2401  as described below. 
         [0041]    A front side  2602  of the door opening mechanism  2415  includes one or more features  2603  (e.g., pads or pins) that correspond to respective features  2431  of the door  2417  ( FIG. 8A ). The features  2603  are adapted to mate with corresponding features  2431  on the door  2417  to ensure proper alignment of the door  2417  with the door opening mechanism  2415  (and therefore, are dimensioned and shaped accordingly). Although the features  2603  are shown as being round or oval shaped, other shapes may be employed. 
         [0042]    The front side  2602  of the door opening mechanism  2415  includes one or more holes  2605  corresponding to the one or more passageways  2433  included in the door  2417  ( FIG. 8A ).  FIGS. 10A-B  illustrate isometric views of a rear of the door opening mechanism  2415 . With reference to  FIGS. 10A-B , a pocket  2701  may be formed in a rear side  2703  of the door opening mechanism  2415 . The pocket  2701  includes a channel  2705  to which the one or more holes  2605  are coupled. The door opening mechanism  2415  includes a fitting  2707  coupled to the channel  2705  via a passageway  2709 . The fitting  2707  of the door opening mechanism  2415  may be coupled to a corresponding fitting  2419  ( FIG. 7A ) of the apparatus  2401  (e.g., for coupling to a vacuum source). A cover  2711  ( FIG. 10B ) may be coupled (e.g., bonded) to the rear side  2703  of the door opening mechanism  2415 , thereby sealing the channel  2705 . The cover  2711  and/or the remainder of the door opening mechanism  2415  may be formed from any suitable material. In at least one embodiment, the channel  2705  may form a U-shape having a width w 1  and a height h. The channel  2705  may be otherwise shaped. 
         [0043]      FIG. 11  is a cross-sectional side view of the door opening mechanism  2415  taken along line  11 - 11  in  FIG. 9B . In one or more embodiments, the feature  2603  may have a radius r 1  and a width w 2 .  FIG. 12  is a cross-sectional side view of the door opening mechanism  2415  (taken along line  12 - 12  in  FIG. 9B ) when the door opening mechanism  2415  is coupled to a substrate carrier door  2417 . 
         [0044]    In operation, the actuator (not shown in  FIG. 12 ;  2421  in  FIGS. 9A-B ) may rotate the door opening mechanism  2415  such that the door opening mechanism  2415  couples to (e.g., mates with) the door  2417 . More specifically, the actuator  2421  may rotate the door opening mechanism  2415  such that the features  2603  of the door opening mechanism  2415  couple to (e.g., are inserted into) respective corresponding features  2431  of the door  2417 , the holes  2605  of the door opening mechanism  2415  align with the passageways  2433  in the door  2417 , and the seals  2435  couple to/seal against an area of the front side  2602  of the door opening mechanism  2415  (e.g., concentric to the holes  2605 ). 
         [0045]    While the door opening mechanism  2415  is coupled to the door  2417  of a substrate carrier  2409 - 2413 , a vacuum is provided (e.g., by a vacuum source (not shown)) to the hole  2605  via the fitting  2419  of the apparatus  2401  (and fitting  2707 , passageway  2709  and channel  2705  of the door opening mechanism  2415 ). Consequently, the hole  2605  provides a vacuum to the passageways  2433  in the door  2417  and the door  2417  is held against the door opening mechanism  2415 . The actuator  2421  then may rotate the door  2417  out of engagement with its respective substrate carrier body so that the door  2417  is approximately horizontal, lowering the door  2417  (e.g., into a housing) below the respective loadport  2403 - 2407 . 
         [0046]    Additionally, in embodiments in which the passageways  2433  are coupled to a mechanism (e.g., vacuum actuated mechanism) for unlatching or unlocking the door  2417  from a remaining portion of a substrate carrier  2409 - 2413 , the vacuum provided by the door actuating mechanism  2415  may serve to actuate such a door unlatching mechanism. For example, the vacuum provided by the door actuating mechanism  2415  (via holes  2605 ) may serve to deflate a bladder around the periphery of the door  2417 , which secures the door  2417  to a body of the substrate carrier  2409 - 2413  when inflated, thereby allowing the door  2417  to be removed. 
         [0047]    The foregoing description discloses only exemplary embodiments of the invention; modifications of the above disclosed apparatus and methods which fall within the scope of the invention will be readily apparent to those of ordinary skill in the art. For instance, the overhead carrier support  111   a  and the overhead transfer flange  113   a  may be formed from any suitable material (e.g., materials that slide freely and exhibit long term wear resistance). Exemplary materials for the overhead carrier support and/or the overhead transfer flange include metals (e.g., stainless steel, aluminum, etc.), plastics (e.g., polycarbonate, polyethelene, other ultra high molecular weight or high density plastics, nylon, PTFE, etc.), or other similar materials. Plastic components may be molded or otherwise fabricated. Further, although in embodiments above, a vacuum is provided to the hole  2605  of the door opening mechanism  2415  via the fitting  2419  of the apparatus  2401 , fitting  2707  of the door opening mechanism  2415 , passageway  2709  and channel  2705 , in other embodiments, vacuum may be provided to the hole  2605  through a different route. In some embodiments, vacuum pressure may be used to activate the latches to lock and unlock the door from the substrate carrier. 
         [0048]    Accordingly, while the present invention has been disclosed in connection with exemplary embodiments thereof, it should be understood that other embodiments may fall within the spirit and scope of the invention, as defined by the following claims.