Pipe assembly having an angled plate and fabrication methods

A pipe assembly is provided, the pipe assembly comprising a first pipe having a side opening on a side surface of the first pipe. A plate in the first pipe is arranged adjacent to the side opening and at an angle relative to a radial axis of the first pipe such that a first side of the plate may be lower than a second side. A vent hole may be proximal the side opening on the side surface of the first pipe.

FIELD OF THE INVENTION

The disclosed embodiments relate generally to a pipe assembly, and more particularly, to a pipe assembly having an angled plate and fabrication methods.

BACKGROUND

Semiconductor processing for patterning a device feature may include dry etch processes which may generate residue. The residue generated by the dry etch process may be removed from the etching chamber together with the exhaust gas via a pump connected to the chamber. An orifice plate in a pipe assembly connected to the pump may be used to filter out large particles in the residue generated during the etching process. The orifice plate may refer to a plate having an orifice.

The large particles in the residue may obstruct the orifice plate in the pipe assembly. The pipe assembly may be connected to an abatement head for removal of harmful gases from the exhaust gas prior to releasing it to the atmosphere. The abatement head may be a scrubber or a convection oven. The obstruction of the orifice plate in the pipe assembly may cause a spike in an exhaust pressure of the pump, subsequently causing the pump to fail. Thus, there is a need to overcome the challenges mentioned above.

SUMMARY

In an aspect of the present disclosure, a pipe assembly is provided. The pipe assembly comprises a first pipe having a side opening on a side surface of the first pipe. A plate in the first pipe may be arranged adjacent to the side opening and at an angle to a radial axis of the first pipe such that a first side of the plate may be lower than a second side. A vent hole may be proximal the side opening on the side surface of the first pipe.

In another aspect of the present disclosure, a pipe assembly is provided. The pipe assembly comprises a first pipe having a side opening on a side surface of the first pipe. A second pipe may be connected to the first pipe at the side opening. A plate in the first pipe may be arranged at an angle to a radial axis of the first pipe such that a first side of the plate may be lower than a second side of the plate. The plate and a bottom surface of the second pipe may be arranged in a continuous plane. A vent hole may be proximal the side opening on the side surface of the first pipe.

In yet another aspect of the present disclosure, a method of fabricating a piping is provided. The method comprises providing a first pipe having a side opening on a side surface of the first pipe. A plate may be attached in the first pipe, whereby the plate may be arranged adjacent to the side opening and at an angle to a radial axis of the first pipe such that a first side of the plate may be lower than a second side. A vent hole may be formed proximal the side opening on the side surface of the first pipe.

Numerous advantages may be derived from the embodiments described below. The embodiments provide a pipe assembly having a plate angled relative to a radial axis of a first pipe that redirects large particles from an etching process residue to a second pipe and a collection reservoir, thereby preventing obstruction of a vent hole and an abatement head connected to the first pipe. The exhaust pressure of a pump connected to the first pipe is maintained at a consistent level thereby increasing the pump lifetime. Interruptions to an etching process between scheduled chamber maintenance are reduced or eliminated leading to cost savings. Chamber maintenance is thereby minimized and labor efficiency is increased.

For simplicity and clarity of illustration, the drawings illustrate the general manner of construction, and certain descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the discussion of the described embodiments of the devices. Additionally, elements in the drawings are not necessarily drawn to scale. For example, the dimensions of some of the elements in the drawings may be exaggerated relative to other elements to help improve understanding of embodiments of the devices. The same reference numerals in different drawings denote the same elements, while similar reference numerals may, but do not necessarily, denote similar elements.

DETAILED DESCRIPTION

The following detailed description is exemplary in nature and is not intended to limit the devices or the application and uses of the devices. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the devices or the following detailed description.

FIG.1Aillustrates a side view of a pipe assembly100, according to an embodiment of the disclosure. Referring toFIG.1A, the pipe assembly100may include a first pipe102connected to one end of a second pipe106, and a third pipe128connected to the other end of the second pipe106. A plate118having a vent hole108may be arranged in the first pipe102. The plate118and the vent hole108are shown in the side view with dotted lines to illustrate an example of the pipe assembly100. The third pipe128may also be connected to a collection reservoir126.

A possible set up and operation of the pipe assembly100is described below. A flange142may connect a top end of the first pipe102to a semiconductor equipment, for example, an etching chamber or any other suitable machine or apparatus that generates particles and/or gas. A flange138may connect a bottom end of the first pipe102to an abatement head or any other suitable machine or apparatus for removal of particles or gas. An exhaust gas generated during an etching operation may flow from the etching chamber to the first pipe102. The exhaust gas may contain a mixture of large and small particles. The large particles, represented by a thick dashed arrow, may be prevented from passing through the vent hole108and may travel through the second pipe106and the third pipe128to the collection reservoir126. The small particles, represented by a thin dashed arrow, may pass through the vent hole108and to the abatement head (not shown). With the above-described assembly, the potential obstruction of the vent hole108may be prevented by the large particles being channeled away through the second pipe106instead of passing through vent hole108.

FIG.1Billustrates a cross-section view of the pipe assembly100, according to an embodiment of the disclosure. Referring toFIG.1B, the pipe assembly100may include the first pipe102having a side opening150on a side surface of the first pipe102. The second pipe106may be connected to the first pipe102at the side opening150on the side surface of the first pipe102. The first pipe102may be made of stainless steel, or any other suitable metal. The second pipe106may be made of stainless steel, or any other suitable metal. In one embodiment, the first pipe102and the second pipe106may be made of the same material. In another embodiment, the first pipe102and the second pipe106may be made of different materials. The plate118may be arranged at an angle to a radial axis172of the first pipe102. The term “radial axis” may refer to an axis along a radius of a cross-section of the first pipe102. Axis172may be perpendicular to a rotational axis of the first pipe102. The plate118may be arranged in the first pipe102and proximal a bottom surface110of the second pipe106. A first side176of the plate118may be lower than a second side120. The first side176of the plate118may be arranged adjacent to the side opening150. In a preferred embodiment, the plate118and the bottom surface110of the second pipe106may be arranged in a continuous plane. In an alternative embodiment, the plate118and the bottom surface110of the second pipe106may be approximately parallel and may be placed on different planes. For example, the bottom surface110of the second pipe106may be placed lower than a bottom rim of the side opening150.

In one embodiment, the vent hole108may be located proximal a center portion of the plate118. In an alternative embodiment, the vent hole108may be located proximal a side portion of the plate118. In yet another embodiment, the plate118may have a smaller surface area than a cross-sectional area of the first pipe102such that an opening is formed between the plate118and a side surface122of the first pipe102. The cross-sectional area of the first pipe102may be taken at an angle parallel to the radial axis172of the first pipe102. In one embodiment, the plate118may be arranged next to the bottom surface110of the second pipe106. The first pipe102may have a top end and a bottom end opposite to the top end. The first pipe102may have an internal width W1parallel to the radial axis172of the first pipe102.

The second pipe106may be positioned at an angle relative to the first pipe102. For example, the bottom surface110of the second pipe106may be at an angle α to the radial axis172of the first pipe102. Angle α may be more than zero degrees. For example, the second pipe106may include a first end112and a second end116opposite to the first end112. The first end112may be placed higher than the second end116. In one embodiment, the first end112may be arranged next to the plate118. The first end112may be placed next to the side opening150in the side surface of the first pipe102. In a preferred embodiment, the first end112may be arranged next to the first side176of the plate118. Although not shown, in another embodiment, the second end116of the second pipe106may be curved downwards to connect directly with the collection reservoir126.

The second pipe106may include an internal width W2. The internal width W2may be substantially similar at both ends112and116, or may differ with one end being wider than the other end. In one embodiment, the internal width W2may be at least equal to the internal width W1to provide a good flow for large particles and gas. The collection reservoir126may be arranged next to the second end116of the second pipe106. In one embodiment, the collection reservoir126may be a bellows. The term “bellows” may refer to an expansion joint that absorbs movement in a pipe system. In one embodiment, the collection reservoir126may be made of stainless steel or any other suitable metal.

The third pipe128may be arranged between the collection reservoir126and the second pipe106. A flange132may connect the collection reservoir126to the third pipe128. The third pipe128may have an upper end and a lower end opposite the upper end. An internal width of the lower end of the third pipe128may be at least equal to the internal width W1of the first pipe102. In one embodiment, the third pipe128may be substantially similar to the first pipe102and flipped 180°. In another embodiment, the third pipe128may be different from the first pipe102. For example, an internal width of the upper end of the third pipe128may be different from the internal width of the bottom end of the first pipe102. The third pipe128may be made of stainless steel, or any other suitable metal. In a preferred embodiment, the third pipe128may be made of the same material as the first102or second106pipes. In an alternative embodiment, the third pipe128may be made of a different material from the first102or second106pipes.

The second end116of the second pipe106may be arranged next to an opening in a side surface of the third pipe128. The opening in the side surface of the third pipe128is shown by a curved outline. The second end116of the second pipe106may be arranged between the upper end and the lower end of the third pipe128. A flange132may be arranged over the lower end of the third pipe128and a flange136may be arranged over the upper end of the third pipe128. The flange132or136may be used to connect to other pipes or another object. The first end112of the second pipe106may be arranged between the top end of the first pipe102and the bottom end of the first pipe102.

FIG.2illustrates a top view of the pipe assembly100shown inFIG.1B, according to an embodiment of the disclosure. From a top down perspective, the first pipe102may be circular, elliptical, or any other suitable shape. The third pipe128may be circular, elliptical, or any other suitable shape. In one embodiment, the first102and the third128pipes may have the same shape. In another embodiment, the first102and the third128pipes may have different shapes. The flanges136and142may surround the third pipe128and the first pipe102, respectively. The vent hole108may be arranged in the plate118. At least part of a perimeter of the plate118may be adjacent to a side surface of the first pipe102. For example, in one embodiment, the perimeter of the plate118may be adjacent to the side surface of the first pipe102, and the plate118may have a vent hole108in the plate118. In an alternative embodiment, part of the perimeter of the plate118may be adjacent to a portion of the side surface of the first pipe102, with the plate118having a notch thereby forming a vent hole108between the plate118and another portion of the side surface of the first pipe102.

FIG.3Aillustrates a top view of the plate118and the vent hole108, according to an embodiment of the disclosure. The plate118may be circular, elliptical, or any other suitable shape. The vent hole108may be circular, elliptical, or any other suitable shape. In one embodiment, the plate118and the vent hole108may have the same shape. In another embodiment, the plate118and the vent hole108may have different shapes. In yet another embodiment, a width of the plate118may be smaller than the internal width W1of the first pipe102such that an opening may be formed proximal a side surface122of the first pipe102. For example, a side surface of the plate118may have a notch or a cut-out portion.

FIG.3Billustrates a cross-section view of the plate118and the vent hole108shown inFIG.3A, according to an embodiment of the disclosure. The plate118and the vent hole108may be placed at an angle θ with respect to the radial axis172of the first pipe102. For example, the angle θ may range between ten (10) to sixty (60) degrees, with a preferred range between twenty five (25) to forty (40) degrees. It should be appreciated that the ranges specified above are exemplary and are not limiting. In an embodiment, angle θ may be approximately equal to angle α shown inFIG.1B. Referring toFIG.3B, in one embodiment, the cross-section view of the plate118including the first side176, the second side120, the top surface and the bottom surface of the plate118may be in the shape of a parallelogram, with the first side176parallel to the second side120. In another embodiment, the first side176of the plate118may not be parallel to the second side120. For example, the first side176of the plate118may be arranged at a different angle to the radial axis172compared to the second side120. In yet another embodiment, the plate118may have a top surface approximately parallel to a bottom surface and rounded side surfaces. In yet another embodiment, the cross-section view of the plate118including the first side176, the second side120, the top surface and the bottom surface of the plate118may be in the shape of a rectangle.

The vent hole108may have a first side surface108aand a second side surface108b. The first and second side surfaces,108aand108b, respectively, may be substantially at right angles to the surface of the plate118or may be slanted at an angle more or less than 90 degrees to the surface of the plate. In a preferred embodiment, the first and second side surfaces,108aand108b, respectively, may be substantially parallel to the first and second sides,176and120, respectively, of the plate118. The first and second sides,176and120, respectively, of the plate118may be substantially perpendicular to the radial axis172, for ease of alignment in the first pipe102. In another embodiment, the vent hole108may be a funnel shape, having a top width smaller than a bottom width. In yet another embodiment, there may be at least two vent holes108arranged in the plate118. The first side surface108amay be arranged lower than the second side surface108b. The first side surface108aof the vent hole108may be proximal the side opening150on the side surface of the first pipe102and the bottom surface110of the second pipe106.

The vent hole108may include a width Wv measured from the first side surface108ato the second side surface108b. In the case where the side surfaces108aand108bare slanted with respect to the surface of the plate118, i.e. not set at right angles to the surface plane, the width Wv may be one of the largest measurements between the first side surface108aand the second side surface108b. The width Wv may have a range not limited to between 6 millimeters and 7 millimeters. In another case, for example, when the vent hole108is not circular, the width Wv may also be one of the largest measurements between the first side surface108aand the second side surface108b. In other words, the width Wv may represent the largest measurement across the vent hole108.

FIGS.4A,4B,5A,5B, and6to8illustrate a process flow for fabricating the pipe assembly100shown inFIG.1B, according to some embodiments of the disclosure. In an alternative embodiment, the pipe assembly100may be fabricated by 3-D printing.

FIG.4Aillustrates a front view of a partially completed pipe assembly100including the first pipe102, a cut152and a side opening150on a side surface of the first pipe102, according to an embodiment of the disclosure. Referring toFIG.4A, the side opening150may be made in the first pipe102by drilling or any other suitable method. A dashed line A-A′ indicates a width of the side opening150. In one embodiment, the side opening150may have a shape of two half ellipses merged along the line A-A′. In another embodiment, the side opening150may be a circle or any other suitable shape. A cut152may be made in the first pipe102to separate the first pipe102into an upper portion and a lower portion. The cut152may be made at the width of the side opening150.

FIG.4Billustrates a cross section view of the partially completed pipe assembly100shown inFIG.4A, according to an embodiment of the disclosure. Referring toFIG.4B, in one embodiment, the cut152may be arranged at the angle θ with respect to the radial axis172of the first pipe102for ease of placing the plate118in the first pipe102. In an alternative embodiment, the cut152may not be made in the first pipe102, for example, when the pipe assembly100is 3-D printed. In a preferred embodiment, an upper rim162aand a lower rim162bof the side opening150may be sloped at substantially similar angles to the angle α to allow a better fit of a second pipe106. An outer perimeter of the side opening150may have a concave shape.

FIG.5Aillustrates a top view of the lower portion of the first pipe102after attachment of a plate118having a vent hole108, according to an embodiment of the disclosure. The plate118may be attached by welding or any other suitable attachment methods to the first pipe102. Even though a gap is shown between the plate118and the first pipe102, the gap may be filled by a weld material to attach the plate118to the first pipe102. Lines158aand158bindicate a top rim of the side opening150. A perimeter of the plate118may be adjacent to an inner perimeter of the first pipe102. A width of the plate118may be smaller than or equal to a width of the side opening150. The width of the side opening150is indicated by a distance between lines158aand158b. In one embodiment, the vent hole108in the plate118may be formed by drilling or any other suitable method. The vent hole108may be placed proximal the side opening150. In an alternative embodiment shown inFIG.5B, the vent hole108may be formed by making a cut-out portion or a notch at an edge portion of the plate118, such that the vent hole108is formed between the plate118and a side surface of the first pipe102.

FIG.6illustrates a cross-section view of the lower portion of the first pipe102shown inFIG.5A, according to an embodiment of the disclosure. Referring toFIG.6, the plate118may be arranged at approximately the angle θ to the radial axis172of the first pipe102such that a first side176of the plate118is lower than a second side120. The first side176of the plate118may be adjacent to the lower rim162bof the side opening150.

FIG.7illustrates a cross-section view of the partially completed pipe assembly100after attaching an upper portion of the first pipe102to the lower portion of the first pipe102and a second pipe106to the first pipe102, according to an embodiment of the disclosure. The attachment may be made by welding, or any other suitable attachment method. The attachment of a first end112of the second pipe106to cover the side opening150in the first pipe102may be made by welding, or any other suitable attachment method. A cross-section of the second pipe106may be circular, elliptical, or any other suitable shapes. In one embodiment, the first end112of the second pipe106may have an angular outer portion (not shown) and a curved inner portion166to complement a curvature of the first pipe102thereby forming a tight seal. The curved inner portion166of the second pipe106may complement a shape of the outer circumference of the side opening150in the first pipe102. Although not shown, from a top down perspective, a portion of the second pipe106proximal the first pipe102may have a semi-circular shape wrapping around the first pipe102. When viewed from the bottom, a portion of the second pipe106proximal the first pipe102may have a semi-circular shape wrapping around the first pipe102. In a preferred embodiment, a first end112of the second pipe106may have the same shape as the second end116and flipped 180°. In an alternative embodiment, the first end112of the second pipe106may have a different shape from the second end116.

FIG.8illustrates a cross-section view of the partially completed pipe assembly100after attaching a third pipe128to the second end116of the second pipe106, according to an embodiment of the disclosure. In a preferred embodiment, the third pipe128may have the same shape as the first pipe102and flipped 180°. For example, the shape of a side opening in the third pipe128may be similar to the shape of the side opening150in the first pipe102. Thereby, the third pipe128may be fabricated in the same manner as the first pipe102as shown inFIGS.4A and4B, without the cut152. In an alternative embodiment, the third pipe128may have a different shape from the first pipe102. The third pipe128may be attached to the second pipe106by welding, or any other suitable attachment method.

The process continues to form the pipe assembly100shown inFIG.1B. A flange132may be attached to a lower end of the third pipe128. A flange136may be attached to an upper end of the third pipe128. A flange138may be attached to a bottom end of the first pipe102. A flange142may be attached to a top end of the first pipe102. The flanges132,136,138and142may be attached by welding, or any other suitable attachment method.

The terms “first”, “second”, “third”, and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the device described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. The terms “left”, “right”, “front”, “back”, “top”, “bottom”, “over”, “under”, and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the device described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein. Similarly, if a method is described herein as comprising a series of steps, the order of such steps as presented herein is not necessarily the only order in which such steps may be performed, and certain of the stated steps may possibly be omitted and/or certain other steps not described herein may possibly be added to the method. Furthermore, the terms “comprise”, “include”, “have”, and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or device that comprises a list of elements is not necessarily limited to those elements, but may include other elements not expressly listed or inherent to such process, method, article, or device.

While several exemplary embodiments have been presented in the above detailed description of the device, it should be appreciated that number of variations exist. It should further be appreciated that the embodiments are only examples, and are not intended to limit the scope, applicability, dimensions, or configuration of the devices in any way. Rather, the above detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the devices, it being understood that various changes may be made in the function and arrangement of elements and method of fabrication described in an exemplary embodiment without departing from the scope of this disclosure as set forth in the appended claims.