PROCESS CHAMBER SUBSTRATE TRANSFER

A processing system is provided including a first chamber and a second chamber. The first chamber includes: a chamber body enclosing an interior volume; an edge ring having a top and a bottom, the edge ring including a first ledge extending inwardly from the top and a second ledge extending inwardly relative to the first ledge. The first ledge is configured to support a substrate and the second ledge is configured to support a susceptor. The first chamber further includes a plurality of heating lamps positioned over the edge ring. The second chamber includes: a chamber body enclosing an interior volume; a first cooling plate; one or more robots in the interior volume of the second chamber, the one or more robots having one or more end effectors positioned over the first cooling plate; and a plurality of lift pins extending through the first cooling plate.

BACKGROUND

Embodiments of the present disclosure generally relate to methods and related equipment for improving the transfer of substrates between chambers and the uniformity of processes performed on the substrates in process chambers, such as a rapid thermal processing.

DESCRIPTION OF THE RELATED ART

The components used in electronic devices are continually becoming smaller. Manufacturing these smaller components presents challenges for handling the smaller components and the thinner substrates on which the components are formed. Furthermore, achieving process uniformity across a substrate during processes, such as rapid thermal processing, becomes more important as the size of the components to be formed continue to shrink.

Accordingly, there is a need for methods and equipment that can improve the handling of thinner substrates and improve the uniformity of the processes performed on the substrates.

SUMMARY

In one embodiment, a processing system is provided comprising: a first chamber comprising: a chamber body enclosing an interior volume; an edge ring positioned in the interior volume, the edge ring having a top and a bottom, the edge ring including a first ledge extending inwardly from the top and a second ledge extending inwardly relative to the first ledge, wherein the first ledge is configured to support a substrate and the second ledge is configured to support a susceptor; and a plurality of heating lamps positioned over the edge ring; and a second chamber coupled with the first chamber, the second chamber comprising: a chamber body enclosing an interior volume; a first cooling plate; one or more robots in the interior volume of the second chamber, the one or more robots having one or more end effectors positioned over the first cooling plate; and a plurality of lift pins extending through the first cooling plate.

In another embodiment, a processing system is provided comprising: a first chamber comprising: a chamber body enclosing an interior volume; an edge ring positioned in the interior volume, the edge ring having a top and a bottom, the edge ring including a first ledge extending inwardly from the top and a second ledge extending inwardly relative to the first ledge, wherein the first ledge is configured to support a substrate and the second ledge is configured to support a susceptor; and a plurality of heating lamps positioned over the edge ring; and a second chamber coupled with the first chamber, the second chamber comprising: a chamber body enclosing an interior volume; and a robot having an end effector that includes a body, a first support and a second support, wherein the body has a top and a bottom, the first support and the second support are positioned on the top of the body, and the second support is movable relative to the first support from a first position to a second position.

In another embodiment, a method of processing a substrate is provided comprising: moving a substrate positioned on a susceptor into an interior volume of a process chamber; positioning the susceptor that is supporting the substrate on a support in the interior volume of the process chamber; performing a process on the substrate in the interior volume of the process chamber; and simultaneously removing the substrate and the susceptor from the interior volume of the process chamber after the process is performed.

In another embodiment, a susceptor for thermal processing of a substrate is provided, the susceptor comprising a disc-shaped body having a first surface, a second surface, and an outer edge connecting the first surface to the second surface, wherein the first surface configured to face a substrate during processing, the first surface is free of any holes, and the susceptor is configured to be repositioned between a process chamber and a cooldown chamber while a substrate is at least partially supported on the first surface.

DETAILED DESCRIPTION

Embodiments of the present disclosure generally relate to processing systems for substrates (e.g., semiconductor substrates) that includes features for improving the handling of the substrates as well as improving the uniformity of the processes performed on the substrates. The processing systems disclosed are configured to transfer a substrate between different chambers in the processing system while the substrate is supported by an underlying support that can be used to support the substrate during the process, such as a susceptor. Supporting the substrate with the susceptor provides additional support for the substrate as the substrate is moved through the processing system. This additional support can be especially useful for handling thinner substrates (e.g., substrates having a thickness of around 100 micron or less than 100 micron) that may be more fragile than the thicker substrates that have been conventionally used. However, this additional support is also useful for substrates having more conventional thicknesses as well. The additional support can also be especially useful when the substrate is formed of material that is transparent to the radiation used to heat the substrate, and the additional substrate support is more opaque than the substrate.

In the following disclosure, the substrates can be supported by a susceptor when the substrate is inserted into a process chamber, such as a rapid thermal processing (RTP) chamber. Because the substrate is already supported by the susceptor before the substrate is inserted into the process chamber, the susceptor does not include any holes or plugs that are typically used to allow lift pins to raise the substrate above the susceptor inside the process chamber. These holes or plugs on the susceptor have often been locations of processing non-uniformities on the substrate as well as locations of damage (e.g., scratches) to the substrate. Because the susceptors provided in this disclosure do not include any holes or plugs for lift pins, these problems relating to process non-uniformities and damage to the areas of the substrate overlying these lift pin locations are eliminated.

Although the following disclosure mainly describes moving a substrate and a susceptor simultaneously into an RTP chamber, the benefits of this disclosure can be applied to any process chamber in which a substrate support, such as a susceptor, support ring, or other support, can be moved with the substrate. Some non-limiting examples of other process chambers in which a substrate support (e.g., a susceptor) can be moved into a process chamber while supporting the substrate include other types of substrate heating chambers, deposition chambers (e.g., chemical vapor deposition chambers, epitaxial deposition chambers, plasma enhanced deposition chambers), etching chambers, lithography chambers, and substrate cleaning chambers.

FIG.1shows a simplified view of a processing system100, according to one embodiment. The processing system100includes a rapid thermal processing (RTP) system200, a transfer chamber150, a cooldown system300, and a controller185. The RTP system200includes a RTP chamber201(first chamber) having an interior volume210. The transfer chamber150(second chamber) includes an interior volume155. The cooldown system300includes a cooldown chamber301(second chamber) having an interior volume310. In some embodiments, the components of the transfer chamber150and the cooldown chamber301can be included in a single chamber.

The transfer chamber150is positioned between the RTP chamber201and the cooldown chamber301. The transfer chamber150can include a transfer robot151. The transfer robot151can include an arm152and an end effector400. The arm152can include an inner portion153and an outer portion154. The inner portion153can be connected to an actuator (not shown) that is configured to rotate the inner portion153, so that the end effector400can be extended and retracted. The outer portion154can also be coupled to an actuator (not shown) that is configured to rotate the outer portion154relative to the inner portion153, so that the end effector400can be extended and retracted. In some embodiments, the end effector400can also include an actuator (not shown) that can be configured to rotate the end effector400relative to the outer portion154.

The transfer robot151can be used to move a substrate50and a susceptor60to and from the interior volume210of the RTP chamber201and to and from the interior volume310of the cooldown chamber301. The susceptor60is positioned below the substrate50and is shown in dashed lines to indicate that the susceptor60is below the substrate50inFIG.1. Notably, in some embodiments, the top surface61(first surface) of the susceptor60does not include any holes or plugs that are conventionally used to allow for movement of lift pins through the susceptor and that have often been associated with damage (e.g., scratches) on the backside of the substrate50. In some embodiments, the susceptor60has a smaller size (e.g., a smaller diameter) than the substrate50which the susceptor60supports. The transfer robot151can move the susceptor60and the substrate50at the same time. The susceptor60can help support the substrate50during movement of the substrate50, for example into and out of the interior volume210of the RTP chamber201as well as into and out of the cooldown chamber301.

In some embodiments, the susceptor60has a disc-shaped body. The disc-shaped body can include the top surface61(first surface), a bottom surface62(second surface) (seeFIG.2), and an outer edge63connecting the top surface61with the bottom surface62. The top surface61is configured to face and/or support a substrate50during processing. In some embodiments, the top surface61and well as the other surfaces62,63can be completely free of unique features, such as holes that allow for the movement of lift pins.

The RTP chamber201can include a plurality of lift pins245and an edge ring280. The lift pins245can raise above the top of the edge ring280when the substrate50and susceptor60are moved into or from the interior volume210of the RTP chamber201. The lift pins245can lower to position the substrate50and susceptor60onto the edge ring280as described in further detail below.

The cooldown chamber301can include a first robot330A, a second robot330B, a first cooling plate321, and a plurality of lift pins345in the interior volume310of the cooldown chamber301. The lift pins345can raise above the top of the first cooling plate321when the substrate50and susceptor60are moved into or from the interior volume310of the cooldown chamber301. The lift pins345can lower to position the substrate50and susceptor60onto the first cooling plate321as described in further detail below. Notably, the lift pins245(FIG.2) and the lift pins345do not directly contact the substrate50, which can eliminate problems, such as damage that can result when a lift pin touches the backside of a substrate. Lift pins can often damage the backside of a substrate with the likelihood of damage being higher when the substrates are heated to elevated temperatures, such as after RTP is performed on a substrate.

Each robot330can include an actuator331, a shaft332, and an end effector335. The end effectors335can be used to grip and/or support the substrate50around the outer edge of the substrate50, so that the substrate50can be removed from susceptor60. After the substrate50is contacted around the outer edge of the substrate50by the end effectors335A,335B, the lift pins345can lower, so that the susceptor60is lowered relative to the substrate50. After the susceptor60is lowered, an external robot (not shown) can remove the substrate50from the end effectors335A,335B and from the cooldown chamber301, and then subsequently position another substrate50in the cooldown chamber301. In some embodiments, a single robot with one or more end effectors can be used in the cooldown chamber301. In one embodiment with a single robot having two end effectors, this single robot can position the end effectors closer to or further away from each other in a similar manner as described herein for the robots330A,330B. InFIG.3, each robot330can be positioned in an outer location in which the end effectors335do not overlie the lift pins345. This location enables the robots330to extend to contact the substrate50around the edge of the substrate50.

The RTP system200further includes the controller185for controlling processes performed by the processing system100. The controller185can be any type of controller used in an industrial setting, such as a programmable logic controller (PLC). The controller185includes a processor187, a memory186, and input/output (I/O) circuits188. The controller185can further include one or more of the following components (not shown), such as one or more power supplies, clocks, communication components (e.g., network interface card), and user interfaces typically found in controllers for semiconductor equipment.

The memory186can include non-transitory memory. The non-transitory memory can be used to store the programs and settings described below. The memory186can include one or more readily available types of memory, such as read only memory (ROM) (e.g., electrically erasable programmable read-only memory (EEPROM), flash memory, floppy disk, hard disk, or random access memory (RAM) (e.g., non-volatile random access memory (NVRAM).

The processor187is configured to execute various programs stored in the memory186, such as programs configured to perform thermal processes in the RTP chamber201as well as movement of the substrate50and susceptor60through the processing system100. During execution of these programs, the controller185can communicate to I/O devices (e.g., inputs, such as sensors and outputs, such as actuators) through the I/O circuits188. For example, during execution of these programs and communication through the I/O circuits188, the controller185can control outputs, such as raising and lowering lift pins245,345and receive information from inputs, such as temperature sensors in the RTP chamber201. The memory186can further include various operational settings used to control the processing system100. For example, the settings can include temperature setpoints and durations for heating the substrate50in the RTP chamber201.

FIG.2shows a side cross-sectional view of the RTP system200, according one embodiment. The RTP system200includes the RTP chamber201, gas sources260, a remote plasma source270, and an exhaust pump275.

In some embodiments, gases from the gas sources260can be provided to the remote plasma source270to generate a plasma that is then provided to the RTP chamber201to clean the interior of the RTP chamber201. In other embodiments, gases from the gas sources260can be provided to the RTP chamber201without going through the remote plasma source270, and these gases can be heated by the RTP chamber201to cause the heated gases to form plasma species (e.g., radicals) to clean the interior of the RTP chamber201. The gases from the gas sources260can include cleaning gases (e.g., hydrogen and oxygen) as well as gases for performing a purge (e.g., an inert gas or nitrogen). The exhaust pump275can be used to exhaust gases from the interior of the RTP chamber201as well as to control the pressure in the interior volume of the RTP chamber201.

The RTP chamber201includes a chamber body202. The chamber body202encloses the interior volume210. The chamber body202includes a top203, a bottom204, and one or more sides205connecting the top203with the bottom204. The RTP chamber201includes a transparent window220that can form part of the top203of the chamber body202.

The RTP chamber201includes an edge ring280. When the substrate50and the susceptor60are inserted in the interior volume210, the substrate50and the susceptor60can be positioned on the lift pins245when the lift pins245are raised above the edge ring280. The substrate50and the susceptor60can be positioned on the lift pins245through a port (not shown), such as a slit valve. The lift pins245can then be lowered to position susceptor60and the substrate50on the edge ring280.

The edge ring280includes a top surface284, a bottom surface285, a first ledge281, a second ledge282, and a sidewall287. The sidewall287can connect the first ledge281with the second ledge282. The first ledge281extends inwardly relative to the top surface284towards a central axis234of the interior volume210. The first ledge281extends inwardly at a vertical location below the top surface284of the edge ring280and above the second ledge282of the edge ring280. The second ledge282extends inwardly relative to the first ledge281towards the central axis234of the interior volume210. The second ledge282extends inwardly at a vertical location below the first ledge281of the edge ring280and above the bottom surface285of the edge ring280. The substrate50can be positioned on the first ledge281of the edge ring280during processing. The susceptor60can be positioned on the second ledge282of the edge ring280during processing.

The RTP chamber201further includes a rotatable cylinder230and a rotatable flange232. The edge ring280is positioned on or connected to (e.g., mounted to) the rotatable cylinder230. The rotatable cylinder230is magnetically coupled to the rotatable flange232. A rotor (not shown) rotates the rotatable flange232about the central axis234. The rotation of the flange232causes the rotatable cylinder230and edge ring280to rotate along with the substrate50and the susceptor60that are positioned on the edge ring280during processing.

As mentioned above, the top surface61of susceptor60does not include any holes, such as holes typically used for lift pins. In some embodiments, there are no holes, recesses, or other unique features on any surface of the susceptor60, and the body of the susceptor60can also be uniform in a radial direction as well as along the azimuth. This higher level of uniformity across the susceptor60allows for improved uniformity in the thermal performance of the susceptor60, which improves the thermal uniformity across the substrate50in the radial direction and along the azimuth when a process (e.g., RTP) is performed on the substrate50. The dual ledges281,282of the edge ring280allows for the gaps to remain quite small (1) between the substrate50and the susceptor60, (2) between the susceptor60and the edge ring280, and (3) between the substrate50and the edge ring280during processing, which can also improve thermal performance. A small gap is maintained between these components to account for thermal expansion. In some embodiments, the susceptor60can be sized to position the outer edge63of the susceptor60at a distance from about 0.01 mm to about 5 mm, such as from about 0.1 mm to about 0.5 mm from the sidewall287of the edge ring280when the susceptor60is positioned on the second ledge282. For example, in some embodiments, the diameter of the susceptor60is smaller than the diameter of the second ledge282(i.e., from the center of the susceptor60to the sidewall287) by a distance from about 0.01 mm to about 5 mm, such as from about 0.1 mm to about 0.5 mm.

In some embodiments, the thermal performance of the susceptor60can have a very high degree of uniformity in the radial direction and along the azimuth. For example, in some embodiments of the susceptor60, the variation in thermal performance (e.g., thermal load) is less than 1%, such as less than 0.1%, such as less than 0.01% along the azimuth around the center of the susceptor60(i.e., for 360 degrees) for each radial distance from the center of the susceptor60to the outer edge of the susceptor60. Similarly, for each angular location, the variation in thermal performance (e.g., thermal load) is less than 5%, such as less than 1%, such as less than 1% in the radial direction from the center of the susceptor60to the outer edge of the susceptor60. Conventional susceptors having unique features at locations across the surface facing the substrate, such as holes for lift pins, cannot achieve this level of thermal uniformity.

The RTP chamber201further includes a reflector228positioned below the edge ring280. The reflector228can be used to reflect radiation back towards the substrate50and susceptor60that are positioned on the edge ring280during processing. The reflector228can include holes that allow the lift pins245to extend and retract through the reflector228to raise and lower the susceptor60and substrate50. Each lift pin245can be connected to a lift pin actuator245A. Each lift pin actuator245A can be positioned below the reflector228.

The RTP chamber201further includes a heating apparatus224positioned over the chamber body202. The heating apparatus224can include a plurality of lamps226. In some embodiments, the plurality of lamps226can be positioned in respective reflective tubes227that are arranged in a hexagonal close-packed array above the transparent window220. In some embodiments, the lamps226are high-intensity tungsten-halogen lamps. In some embodiments, the heating apparatus224includes hundreds or thousands of the lamps226. The heating apparatus224can be configured to rapidly heat components in the interior volume210at rates greater than 100° C./second, such as greater than 300° C./second to temperatures from 600° C. to 1350° C.

During processing, the reflector228reflects radiation emitted from the substrate50and susceptor60back toward the substrate50and the susceptor60. In some embodiments, the reflector228can be supported on a base253. The base253can form part of the chamber bottom204. In some embodiments, the base253can be made of metal to heat sink excess radiation, especially during cool down portions of a process. In some embodiments, a cooling fluid (e.g., water) can be circulated through the base253during a process performed on a substrate.

In some embodiments, the susceptor60can be formed of silicon carbide, a base material (e.g., a carbide) coated with silicon carbide, aluminum oxide (Al2O3) or from one or more ceramic materials. The reflector228can be formed of materials, such as copper, copper coated with nickel, gold, aluminum (e.g., polished aluminum), and aluminum coated with nickel.

In some embodiments, the lamps226can be arranged in a ring-like pattern about the central axis234. Control circuitry can be used to vary the voltage delivered to the lamps226in the different zones to control the radial distribution of radiant energy during processes, so that the temperature of different locations on the substrate50or other components, such as the reflector228can be controlled during a process.

The RTP chamber201can further include a plurality of pyrometers240and a plurality of light pipes242. Each light pipe242can extend from one of the pyrometers240to a location below the edge ring280. For example, each light pipe242can extend to a different aperture in the reflector228. Each pyrometer240can receive radiation through a corresponding light pipe242to monitor temperatures at different locations (e.g., different radial locations) on the substrate50during processing.

FIG.3is a side view of the cooldown system300fromFIG.1, according to one embodiment. The cooldown system300includes the cooldown chamber301and a cooling source360. In one embodiment, the cooling source360is a cooling water source that can provide cooling water to the cooldown chamber301to assist in cooling the substrate50and the susceptor60after the substrate50and susceptor60are heated to high temperatures in the RTP chamber201(seeFIG.2).

The cooldown chamber301includes a chamber body302enclosing the interior volume310of the cooldown chamber301. The chamber body302includes a top303, a bottom304, and one or more sidewalls305. The cooldown chamber301further includes a base315and a first cooling plate321positioned over (e.g., on) the base315. The cooling source360can be fluidly coupled to the first cooling plate321. Cooling fluid can be provided to the first cooling plate321from the cooling source360to assist in cooling the substrate50and the susceptor60.

The cooldown chamber301further includes the lift pins345. Each lift pin345can be coupled to a lift pin actuator345A. Each lift pin actuator345A can be configured to raise and lower the lift pin345that is coupled to that lift pin actuator345A. The base315and the first cooling plate321can each include holes to allow the movement of the lift pins345to raise and lower the susceptor60and the substrate50relative to the top surface of the first cooling plate321.

The cooldown chamber301can further include a second cooling plate322positioned over the first cooling plate321. The cooling source360can be fluidly coupled to the second cooling plate322. Cooling fluid can be provided to the second cooling plate322from the cooling source360to assist in cooling the substrate50and the susceptor60. In some embodiments, the second cooling plate322can be coupled to an actuator325through a shaft326. The actuator325can be configured to move the shaft326to raise and lower the second cooling plate322, so that the second cooling plate322can be positioned closer to the substrate50during cooling. The actuator325can extend the shaft326and second cooling plate321from a primary position to a secondary position that is located closer to the first cooling plate321than the primary position. In some embodiments, the actuator325can mounted to or in a ceiling316of the cooldown chamber301.

The cooldown chamber301further includes the first robot330A and the second robot330B. The robots330can be used to remove the substrate50from the susceptor60and to receive a new substrate50when a new substrate50is inserted into the cooldown chamber301by an external robot (not shown). As described above, each robot330can include an actuator331, a shaft332, and an end effector335. The shaft332connects the actuator331to the corresponding end effector335. Each actuator331can be configured to extend and retract the shaft332horizontally to move the corresponding end effectors335closer to or further away from a central vertical axis C of the interior volume310, so that the end effectors335can contact the substrate50. Each actuator331can extend the shaft332from a first position to a second position in which the corresponding end effector335can contact the substrate50at or near the edge of the substrate50.

In some embodiments, each end effector335can include an extension336. The extension336extends inwardly towards the central vertical axis C relative to the remainder of the end effector335. The extension336can be configured to be positioned under the outer edge of the substrate50when the substrate50is removed from the susceptor60. In some embodiments, each actuator331can also be configured to move the shaft332and corresponding end effector335vertically. For example, each actuator331can position the extension336of the corresponding end effector335under the outer edge of the substrate and then the actuator331can move the end effector335upward to assist with (1) removing the substrate50from the susceptor60or (2) removing a new substrate50from an external robot (not shown) when the external robot inserts the new substrate50into the cooldown chamber301.

FIG.4Ais a partial side view of the end effector400of the transfer robot151fromFIG.1, according to one embodiment. The end effector400includes a blade410(body), a plurality of support pins415, a first support430, and a second support440. The blade410includes a top surface411and a bottom surface412. The plurality of pins415, the first support430, and the second support440are positioned over (e.g., directly on) the top surface411of the blade410. The plurality of pins415can include any number of pins, such as two, three, or greater than ten.

The first support430includes a top surface434and a bottom surface435. The first support430further includes a first ledge431and a second ledge432extending inwardly towards the second support440. The first ledge431is located below the top surface434and above the second ledge432. The second ledge432is located below the first ledge431and above the bottom surface435. The second ledge432horizontally extends further relative to an inner edge436of the top surface434towards the second support440than the first ledge431extends in the same direction. The first ledge431is configured to support the substrate50. The second ledge432is configured to support the susceptor60.

The second support440can be positioned 180 degrees apart from the first support430. The second support440includes a top surface444and a bottom surface445. The second support440further includes a first ledge441and a second ledge442extending inwardly towards the first support430. The first ledge441is located below the top surface444and above the second ledge442. The second ledge442is located below the first ledge441and above the bottom surface445. The second ledge442horizontally extends further relative to an inner edge446of the top surface444towards the first support430than the first ledge441extends in the same direction. The first ledge441is configured to support the substrate50. The second support440further includes a recess443between the first ledge441and the top surface444of the second support440. The top of the second support440can overhang the first ledge441. The recess443can have a height that is slightly greater than the thickness of the substrate50. A portion of the edge of the substrate50can be positioned in the recess443as described below. In some embodiments, the recess443can have a height that is slightly greater than the thickness of the substrate50, so that the recess443can assist in preventing movement of the substrate relative to the supports430,440when the substrate50is transferred between chambers. The second ledge442is configured to support the susceptor60.

In one embodiment, the first support430is configured to be stationary while the second support440is configured to be a movable support. The end effector400can further include an actuator425and a shaft426that are positioned over the top surface411of the blade410. The second support440can be coupled to the actuator425through the shaft426. The actuator425can be configured to extend and retract the shaft426to move the second support440closer to or further from the first support430. For example, the actuator425can extend the shaft426from a first position to a second position that is closer to the first support430than the first position.

FIG.4Bis a partial side view of the end effector400fromFIG.1with the substrate50and the susceptor60positioned on the end effector400, according to one embodiment. The susceptor60can be positioned on the support pins415and the second ledge432of the first support430. The substrate50is positioned on top of the susceptor60. The substrate50can additionally be supported by the first ledge431of the first support430. The substrate50and the susceptor60can be in the position shown inFIG.4B, for example after the lift pins245(seeFIG.2) or the lift pins345(seeFIG.3) lower the susceptor60onto the end effector400.

FIG.4Cis a partial side view of the end effector400fromFIG.1with the substrate50and the susceptor60positioned on the end effector400in a secured position, according to one embodiment. The view inFIG.4Cis the same as the view inFIG.4Bexcept that the substrate50and the susceptor60are also supported and secured by the second support440. The actuator425has extended the shaft426to move the second support440from the non-supporting position shown inFIG.4Bto the supporting position shown inFIG.4C. In the supporting position ofFIG.4C, the substrate50is supported by the first ledge441of the second support440, and the susceptor60is supported by the second ledge442of the second support440. A portion of the outer edge of the substrate50is also moved into the recess443(seeFIG.4B), which can assist in securing the substrate50during movement of the end effector400.

FIG.5is a process flow diagram of a method5000for processing a substrate50in the processing system100fromFIG.1, according to one embodiment. The method5000is described in reference toFIGS.1-5. The method5000can be executed by the controller185.

The method begins at block5002. At block5002with reference toFIG.3, a new substrate50is provided to the interior volume310of the cooldown chamber301and the new substrate50is received by the end effectors335A,335B. The new substrate50can be inserted into the interior volume310of the cooldown chamber301by an external robot (not shown). At block, the susceptor60is already on the first cooling plate321or on the lift pins345in the interior volume310of the cooldown chamber301when the new substrate50is provided to the interior volume310of the cooldown chamber301.

In one embodiment, the external robot can lower the new substrate50onto the extensions336of the end effectors335before the external robot is removed from the cooldown chamber301. In another embodiment, the actuators331can raise the end effectors335to lift the new substrate50from the external robot before the external robot is removed from the cooldown chamber301. In some embodiments, the end effectors335are extended in the horizontal direction, so that the substrate50can be gripped by the end effectors335. After the substrate50is gripped by the end effectors335, the end effectors335can be raised or the external robot (not shown) can be lowered and removed from the cooldown chamber301.

At block5004with reference toFIG.3, the lift pins345are raised to raise the susceptor60to a height where the susceptor60contacts the bottom of the substrate50or to a height where the susceptor60lifts the substrate50from the end effectors335. In some embodiments, the actuators331can retract the end effectors335away from the substrate50after the substrate50is supported by the susceptor60.

At block5006with reference toFIGS.1,3, and4A-4C, the end effector400of the transfer robot151is inserted into the interior volume310of the cooldown chamber301, and the lift pins345are lowered to position the susceptor60and the substrate50onto the end effector400, for example as shown inFIG.4B. The actuator425can then move the second support440to the position shown inFIG.4C, so that the second support440provides support to the susceptor60and the substrate50. In the position shown inFIG.4C, the substrate50is positioned on the first ledge441and secured in the recess443of the second support440, which helps prevent any unintended movement of the substrate50when the substrate50is moved by the transfer robot151.

At block5008with reference toFIGS.1,2,3,4B, and4C, the transfer robot151simultaneously moves the susceptor60and the substrate50(1) from the interior volume310of the cooldown chamber301, (2) through the interior volume155of the transfer chamber150, and (3) into the interior volume210of the RTP chamber201. The transfer robot151can keep the second support440in the position shown inFIG.4Cwhile moving the substrate50and susceptor60from the cooldown chamber301to the RTP chamber201. After the transfer robot151positions the substrate50and the susceptor60in the intended position over the edge ring280of the RTP chamber201, the transfer robot151can move the second support440back to the position shown inFIG.4Bto allow the substrate50and susceptor60to easily be removed from the end effector400of the transfer robot151.

At block5010with referenceFIGS.2and4B, the lift pins245in the RTP chamber201are raised to lift the susceptor60and the substrate50from the end effector400of the transfer robot151. The end effector400is then removed from the interior volume210of the RTP chamber201.

At block5012with reference toFIG.2, the lift pins245are lowered to position the substrate50and the susceptor60on the edge ring280and a process, such as RTP, is performed on the substrate50. The substrate50and the susceptor60can be positioned on the edge ring280as shown inFIG.2during the process performed on the substrate50.

At block5014, with reference toFIGS.2,4B, and4C, the substrate50and the susceptor60are positioned back on the end effector400of the transfer robot151after the process performed on the substrate50at block5012is complete. After the process on the substrate50is completed, the lift pins245are raised to lift the substrate50and the susceptor60above the edge ring280, and the end effector400of the transfer robot151is inserted into the interior volume210below the substrate50and the susceptor60. The lift pins245are then lowered to position the substrate50and the susceptor60onto the end effector400in the position shown inFIG.4B. The transfer robot151then moves the second support440to the position shown inFIG.4C, so that the susceptor60and the substrate50are in a secured position for movement out of the RTP chamber201.

At block5016with reference toFIGS.1,2,3,4B, and4C, the transfer robot151simultaneously moves the susceptor60and the substrate50(1) from the interior volume210of the RTP chamber201, (2) through the interior volume155of the transfer chamber150, and (3) into the interior volume310of the cooldown chamber301. The transfer robot151can keep the second support440in the position shown inFIG.4Cwhile moving the substrate50and susceptor60from the RTP chamber201to the cooldown chamber301. After the transfer robot151positions the substrate50and the susceptor60in the intended position over lift pins345in the cooldown chamber301, the transfer robot151can move the second support440back to the position shown inFIG.4Bto allow the substrate50and susceptor60to easily be removed from the end effector400of the transfer robot151. During blocks5008and5016, the susceptor60is configured to be repositioned between the RTP chamber201and the cooldown chamber301while the substrate50is at least partially supported on the first surface61of the susceptor60. The regions of the substrate50near the outer edge of the substrate50can be supported by the ledges431,441of the supports430,440on the end effector400.

At block5018with reference toFIG.3, a cooldown process is performed on the substrate50and susceptor60after the lift pins345are: (1) raised to remove the substrate50and susceptor60from the end effector400; and (2) lowered to position the substrate50and susceptor60onto the first cooling plate321. The end effector400can be removed from the interior volume310after the substrate50and the susceptor60are positioned on the lift pins345. Cooling fluid (e.g., cooling water) can be provided to flow through the first cooling plate321to increase the rate at which the substrate50and susceptor60cool down.

In embodiments that include the second cooling plate322, cooling fluid (e.g., cooling water) can be provided to flow through the second cooling plate322to increase the rate at which the substrate50and susceptor60cool down. In some of these embodiments, the second cooling plate322can be lowered to be positioned closer to the substrate50and the first cooling plate321to further increase the cooling rate for the substrate50and susceptor60. In some embodiments, the substrate50can be separated from the susceptor60prior to cooling, so that the bottom surface of the substrate50and the top of the susceptor60are not covered. For example, the substrate50can be supported by the end effectors335and the susceptor60can be lowered onto the first cooling plate321. Furthermore, in some embodiments, the cooldown chamber301can be modified to be a batch cooldown chamber in which multiple substrates and susceptors can be cooled down at the same time. In some of these batch cooldown chamber embodiments, the cooldown chamber can include cooling plates similar to cooling plates321,322that that are spaced apart horizontally and/or vertically. A batch cooldown chamber can be useful, for example when the cooldown process takes longer than the process (e.g., RTP) performed in the process chamber.

In some embodiments, a cooldown chamber can include a stack of three or more cooling plates for cooling three or more pairs of substrates and susceptors. In some of these embodiments, the cooldown chamber can further include a single common robot (e.g., robot330A) that can be configured to separate a substrate50from a susceptor60on each cooling plate in the cooldown chamber.

At block5020with reference toFIG.3, after the substrate50has cooled to a target temperature, the lift pins345can raise the substrate50and susceptor60above the first cooling plate321, and the robots330can be used to position the substrate50on the end effectors335of the robots330. The robots330A,330B can extend the end effectors335to a position at which the end effectors335can support the substrate50. Before raising the lift pins345, the second cooling plate322can be raised if the second cooling plate was lowered during block5018. After the substrate50is positioned on and/or gripped by the end effectors335, the lift pins345can be lowered, so that the susceptor60is not in the way when the substrate50is removed from the cooldown chamber301. In some embodiments, the susceptor60can lowered back onto the first cooling plate321, so that the susceptor60can continue to cool. In some embodiments, the cooldown chamber301can include one or more temperature sensors (not shown) to assist in determining when the substrate50has cooled to a target temperature. In other embodiments, the controller185can execute a timer to determine when the substrate has cooled to a target temperature.

At block5022with reference toFIG.3, an external robot (not shown) can be inserted into the interior volume310of the cooldown chamber301, and the substrate50can be positioned on the external robot. The external robot can be inserted below the substrate50. In some embodiments, the external robot can raise in the interior volume310to lift the substrate50from the end effectors335A,335B. In other embodiments, the robots330can lower the corresponding end effectors335A,335B to lower the substrate50onto the external robot. In some embodiments, the external robot can have an end effector with a similar shape as the blade410of the end effector400(seeFIG.1).

At block5024with reference toFIG.3, the external robot (not shown) removes the substrate50from the interior volume310of the cooldown chamber301. After block5024, the method5000can be repeated to process another substrate50. The method5000can be repeated any number of times.

While the foregoing is directed to examples of the present disclosure, other and further examples of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.