INTERFACE TOOL AND METHODS OF OPERATION

Some implementations described herein provide a gas curtain system. The gas curtain system includes various components to prevent a gas flowing within a chamber of an interface tool from flowing through an opening into a transport carrier adjacent to the interface tool. The gas curtain system may include a gas distribution component along an edge of the opening that generates a flow of another gas across the opening towards an opposite edge of the opening. In this way, the gas from the chamber is prevented from entering the transport carrier. By preventing the gas from the chamber from entering the transport carrier, a relative humidity within an environment of the transport carrier is maintained such that condensation of moisture on one or more semiconductor wafers within the transport carrier is mitigated.

BACKGROUND

A semiconductor wafer may be processed in various processing tools in a semiconductor fabrication facility to produce various integrated circuits and/or semiconductor devices. A semiconductor wafer may be transported throughout the semiconductor fabrication facility and/or between the processing tools in the semiconductor fabrication facility.

A plurality of semiconductor wafers and/or other types of substrates may be transported throughout a semiconductor fabrication facility in a transport carrier. A transport carrier may include a wafer cassette, a front-opening unified pod (FOUP), a pod, a container, or a similar type of device. To transfer a semiconductor wafer from a transport carrier to a processing tool, the transport carrier may be placed in and/or on a load port associated with the processing tool. A transport tool included in an interface tool (e.g., an equipment front end module (EFEM) or similar type of interface tool) that is situated between the processing tool and the load port may remove the semiconductor wafer from the transport carrier. The transport tool may transfer the semiconductor wafer from the transport carrier to the processing tool through a chamber of the interface tool. The transport tool may perform the above-described process in reverse to transfer the semiconductor wafer from the processing tool to the transport carrier after processing.

DETAILED DESCRIPTION

In some cases, a transport tool (e.g., a robot arm) included in an interface tool (e.g., an equipment front-end module (EFEM) or similar type of interface tool) situated between a processing tool and a load port may transfer semiconductor wafers between a transport carrier (e.g., a wafer cassette, a front-opening unified pod (FOUP), a pod, a container, or a similar type of device) and the processing tool (e.g., a deposition tool, an etch tool, among other examples.).

An environment within a chamber of the interface tool may be conditioned by providing a flow of a gas within the chamber to generate a positive pressure (e.g., positive relative to an environment external to the chamber) that assists maintaining cleanliness in the chamber of the interface tool (e.g., prevent particulates that may be in an environment surrounding the interface tool from entering the chamber). In some implementations, the gas may be provided to the chamber through a fan filter unit (FFU), which filters the gas prior to directing the gas downward into the chamber.

An example semiconductor wafer transfer operation by the interface tool may include the transport tool transferring a semiconductor wafer from the transport carrier, through the chamber, and to a processing tool such as a deposition tool (e.g., a cobalt deposition tool, a tungsten deposition tool, a copper deposition tool, among other examples). As part of performing the semiconductor wafer transfer operation, the interface tool may open a door of the transport carrier to enable the transport tool to perform the transfer (e.g., retrieve the semiconductor wafer from the transport carrier through an opening and present the semiconductor wafer to the processing tool). While the door is open, the gas from the chamber (e.g., air from the chamber having a high moisture content) may flow into the transport carrier.

In some cases, the gas provided by the FFU to the chamber of the interface tool may have a relatively high moisture content (e.g., relative to the moisture content in the transport carrier). As a result, when the gas from the chamber flows into the transport carrier, a relative humidity of an environment of the transport carrier may increase. The increased relative humidity in the transport carrier may cause moisture to condensate on semiconductor wafers within the transport carrier. The moisture condensation may cause defect formation (e.g., corrosion of a deposited metal) of integrated circuit devices (e.g., structures of the integrated circuit devices) on the semiconductor wafers either while staged within the transport carrier or during processing by the processing tool. Such defects may reduce manufacturing yield of the integrated circuit devices (e.g., time-zero yield), may cause the integrated circuit devices to be allocated to lower-tier markets (e.g., a market that uses integrated circuit devices with partial functionality), or may reduce a reliability of the integrated circuit devices during a field use (e.g., increase a failure in time (FIT) rate), among other examples.

Some implementations described herein provide a gas curtain system. The gas curtain system includes various components to prevent a gas flowing within a chamber of an interface tool from flowing through an opening into a transport carrier adjacent to the interface tool. The gas curtain system may include a gas distribution component along an edge of the opening that generates a flow of another gas across the opening towards an opposite edge of the opening. In this way, the gas from the chamber is prevented from entering the transport carrier. By preventing the gas from the chamber from entering the transport carrier, a relative humidity within an environment of the transport carrier is maintained such that condensation of moisture on one or more semiconductor wafers within the transport carrier is avoided, which minimizes and/or prevents corrosion during a processing of the semiconductor wafers by a processing tool such as a deposition tool.

Moreover, the gas curtain system may include a controller and one or more sensors to collect sensor data to automate one or more operating aspects of the gas curtain system, which may increase effectiveness of the gas curtain system, increase operating efficiency of the gas curtain system (and the interface tool), and increase a yield of product manufactured by a processing tool that receives semiconductor wafers from the interface tool.

FIGS.1A-1Care diagrams of an example semiconductor processing environment100that includes a processing tool including a gas curtain system described herein. The semiconductor processing environment100may include, or may be included in, a semiconductor fabrication facility, a semiconductor foundry, a semiconductor processing facility, a semiconductor clean room, and/or another environment in which semiconductor wafers and/or devices are processed. The semiconductor processing environment100may also include, or be included in, a factory floor of an original equipment manufacturer (OEM) of semiconductor tools.

FIG.1Aillustrates a cross-sectional view of the semiconductor processing environment100. As shown inFIG.1A, the semiconductor processing environment100includes an interface tool102configured to transfer a semiconductor wafer104between a transport carrier106supported on a load port108and a processing tool110, among other tools and/or devices.

The semiconductor wafer104may be transferred directly into a processing area of the processing tool110, may be transferred to a staging area of the processing tool110, or may be transferred to another area of the processing tool110. Additionally and/or alternatively, a semiconductor wafer104may be transferred from the processing tool110to the transport carrier106.

The interface tool102includes a chamber112having an environment114, an aligner116positioned at a location within the chamber112, and a transport tool118(e.g., a robot arm or another type of transport tool) positioned at another location within the chamber112. The environment114within the chamber112may have particular properties, such as a particular temperature (e.g., in degrees Celsius, or °C), a particular cleanliness (e.g., cleanroom classification corresponding to a quantity of particles of a particular size per cubic meter), and/or a particular relative humidity (e.g., RH%), among other examples. The aligner116and the transport tool118may be configured to perform one or more operations to align and transfer the semiconductor wafer104between the transport carrier106and the processing tool110, including transporting the semiconductor wafer104through the chamber112and to the processing tool110.

In some implementations, the aligner116changes an orientation of the semiconductor wafer104so that transport tool118provides semiconductor wafers104to the processing tool110in a consistent orientation. Such a consistent orientation may increase quality and yield. For example, if the processing tool110is a deposition tool, a consistent orientation of the semiconductor wafer104during a series of deposition processes (e.g., during creation of a multilayer material stack) may reduce interlayer stresses that cause defects in structures of the semiconductor wafer104. As another example, a consistent orientation for a plurality of semiconductor wafers104that are to be processed in a wafer lot may increase the repeatability and may increase the consistency of processing results for the plurality of semiconductor wafers104.

The transport carrier106may include a wafer cassette, a FOUP, a pod, a container, or a similar type of device configured to hold and/or store a plurality of semiconductor wafers including the semiconductor wafer104. An environment120within the transport carrier106may have certain properties, such as a particular temperature (e.g., in degrees Celsius, or °C), a particular cleanliness (e.g., cleanroom classification corresponding to a quantity of particles of a particular size per cubic meter), and/or a particular relative humidity (e.g., RH%), among other examples.

The transport carrier106may be positioned on the load port108adjacent to the chamber112to interface with an opening122in a side of the chamber112. The load port108may receive the transport carrier106from a transport robot, a transport cart, an overhead hoist transport (OHT), or another device configured to move transport carriers to and from various locations in the semiconductor processing environment100.

The transport carrier106includes a door124that, when open (or removed from the transport carrier106) as shown inFIG.1A, provides access for the transport tool118to transport the semiconductor wafer104through the opening122. When closed (or when the door124is installed on the transport carrier106), the door124may isolate the environment120of the transport carrier106from the environment114of the chamber112(e.g., prevent a flow of a gas from one environment to another, among other examples) and/or from the environment within the semiconductor processing environment100.

In some implementations, the processing tool110includes a deposition tool (e.g., a processing tool configured to deposit one or more layers of a material such as tungsten, among other examples, onto the semiconductor wafer104). In such an implementation, one or more processes performed by the processing tool110(e.g., a sputtering process, a chemical vapor deposition process, or a physical vapor deposition process that deposits the layer of the material onto the semiconductor wafer104) may be sensitive to moisture on the semiconductor wafer104(e.g., water that condenses onto surfaces or metal layers of the semiconductor wafer104while the semiconductor wafer104is positioned in the transport carrier106prior to transfer of the semiconductor wafer104to the processing tool110, among other examples). For example, moisture on the semiconductor wafer104may cause defects (e.g., corrosion or pitting, among other examples) during a tungsten deposition process performed by the processing tool110. Such defects may decrease yield of semiconductor devices processed by the processing tool110and/or operating efficiencies of the processing tool110.

In other implementations, the processing tool110includes a plating tool (e.g., an electroplating tool configured to deposit one or more metal layers onto the semiconductor wafer104), an exposure tool (e.g., an extreme ultraviolet (EUV) tool, an electron beam (e-beam) tool), or etch tool (e.g., a wet etch tool, a dry etch tool), or another type of processing tool. Similar to the example implementation in which the processing tool110includes a deposition tool, processing of the semiconductor wafer104by each of these additional example implementations may be negatively impacted by moisture that has accumulated onto surfaces or metal layers of the semiconductor wafer104.

The interface tool102includes a gas curtain system126, which will be described in greater detail in relation toFIGS.1B and1C. When active, the gas curtain system126creates a barrier across the opening122to reduce a likelihood of a gas within the environment114from entering the environment120. By reducing the likelihood of the gas within the environment114from entering the environment120, the gas within the environment114is less likely to mix with another gas within the environment120. In this way, one or more properties (e.g., a relative humidity, a temperature, an oxygen concentration, or a contamination level, among other examples) of the environment120may be maintained within particular ranges (or may be maintained to satisfy one or more thresholds) to prevent moisture accumulation on the semiconductor wafer104.

The gas curtain system126is configured to generate a flow of a gas128across the opening122, which provides the barrier across the opening122. The flow of the gas128may include a mixture of one or more gases such as a dry air gas, an extreme clean dry air (XCDA) gas, a nitrogen (N2) gas, a nitrogen-based gas, or another type of inert gas that resists chemically reacting with the materials that may be present on the semiconductor wafer104, among other examples.

In some implementations, a mixture included in the flow of the gas128includes a total organic content such as a total organic carbon content that is in a range of approximately 1 part per billion to approximately 10 parts per billion. By selecting a total organic content within this range, a relative humidity within the environment120and or contamination within the environment120may be maintained below levels that reduce yield of the semiconductor wafer104during processing of the semiconductor wafer104by the processing tool110. However, other values for the total organic content are within the scope of the present disclosure.

As shown inFIG.1A, a controller130(e.g., a processor, a combination of a processor and memory, among other examples) is communicatively connected to the gas curtain system126. The controller130, or portions of the controller130, may be included or distributed across the gas curtain system126, the load port108, the interface tool102, and/or the transport carrier106, among other examples.

The controller130may provide signals to the gas curtain system126to adjust settings of components of the gas curtain system126and/or to control one or more properties of the flow of the gas128based on one or more detected conditions. For example, the controller130may provide one or more signals to the gas curtain system126based on environmental properties detected within the environment120(e.g., a temperature, a relative humidity, an oxygen concentration, and/or a contamination level, among other examples). As another example, the controller130may provide one or more signals to the gas curtain system126based on a position of the door124(e.g., open, partially open, or closed, among other examples). As another example, the controller130may provide one or more signals to the gas curtain system126based on a position of the semiconductor wafer104(e.g., a detected position of the semiconductor wafer104as the semiconductor wafer104passes through the opening122during a transfer operation).

The flow of the gas128may inhibit, restrict, and/or reduce the likelihood of another gas from transferring from the environment114of the chamber to the environment120of the transport carrier106. As is described in connection withFIG.1Band elsewhere herein, inhibiting the gas from transferring from the environment114to the environment120reduces and/or prevents the likelihood of an increase in a relative humidity of the environment120.

FIG.1Billustrates a view of example gas flows within the semiconductor processing environment100. A flow of a gas132is provided through the chamber112to prevent the ingress of humidity, oxygen, and/or contaminants (e.g., dust and other particles) from open areas of the semiconductor processing environment100external to the chamber112. The flow of the gas132protects the semiconductor wafer104from contamination (or reduces the likelihood of contamination) during a transfer operation in which the semiconductor wafer104is transferred through the chamber112.

In some implementations, and as illustrated inFIG.1B, the flow of the gas132is generated by a fan filter unit (FFU)134(e.g., a fan or blower with a high-efficiency particulate air (HEPA) filter or another type of air filter) that draws in a gas from a plenum136. The gas from the plenum136may be mixed with a gas138and provided through a rectifier140to create the flow of the gas132. Additionally and/or alternatively, the FFU134may draw in the gas from an environment in the semiconductor processing environment100.

In some implementations, the gas138corresponds to the gas from the plenum136. In some implementations, the gas138corresponds to a gas circulating within the interface tool102. In some implementations, the gas138includes one or more additional gases provided to the interface tool102by a gas supply system (e.g., a gas supply system may inject an XCDA or an N2gas near an exit of the FFU134). In some implementations, the gas138includes a gas from an environment surrounding the interface tool102(e.g., air from an environment surrounding the interface tool102may flow into the interface tool102through openings, doors, or vents within the interface tool102).

The flow of the gas132may include a closed-loop flow or an open-loop flow. As an example, and for a closed-loop flow, the interface tool102may be equipped with fans, pumps, and/or additional components that circulate the flow of the gas132within the interface tool102and return the flow of the gas132to the plenum136. As another example, and for an open-loop flow, the interface tool102may be equipped with fans and/or vents that exhaust the flow of the gas external to the interface tool102(e.g., to the environment in the semiconductor processing environment100and/or external to the semiconductor processing environment100).

In some implementations, the flow of the gas132includes one or more properties, such as a flow velocity (e.g., meters per second), a flow rate (e.g., liters per second), a Reynolds number indicating a degree of laminarity, and/or a direction of flow, among other examples. Moreover, the flow of the gas132may include a mixture having one or more properties such as a temperature, a cleanliness, and/or an amount of oxygen content, among other examples. Furthermore, and in some implementations, the gas132has a relatively high moisture content142(e.g., a greater amount of water vapor in comparison to a gas within the environment120of the transport carrier106).

A gas system144circulates a flow of a gas146within the transport carrier106. In some implementations, and as shown inFIG.1B, the gas system144is integrated as part of the load port108. In some implementations, the gas system144(including one or more subsystems of the gas system144) is separate from the load port108. In some implementations, the gas system144is integrated as part of the transport carrier106.

The flow of the gas146that is circulated within the transport carrier106may include a mixture of one or more gases such as a dry air gas, an extreme clean dry air (XCDA) gas, a nitrogen (N2) gas, a nitrogen-based gas, or another type of inert gas that resists chemically reacting with the materials that may be included on the semiconductor wafer104. Properties of the flow of the gas146may depend on a type of gas or a mixture of gases used for the flow of the gas146. For example, in an implementation in which an XCDA gas is used, the XCDA gas may include properties such as an oxygen (O2) content that is less than approximately 21% and a relative humidity that is less than approximately 5%. In an implementation using an N2gas, the N2gas may include properties such as an O2that is less than approximately six parts per million (ppm) and a relative humidity that is less than approximately 1%. The flow of the gas146may include a relatively low moisture content148(e.g., a lesser amount of water vapor in comparison to the flow of the gas132within the environment114of the chamber112).

The semiconductor wafer104may accumulate moisture from one or more mixtures of gases in the semiconductor processing environment100. For example, and as shown inFIG.1B, the position of the aligner116may cause the aligner116to deflect the flow of the gas132(e.g., the flow of the gas132having the relatively high moisture content142) towards the opening122. The flow of the gas132may pass through the opening122to mix with the flow of the gas146(e.g., the flow of the gas146having the relatively low moisture content148) and increase the relative humidity of the environment120. In these cases, moisture may accumulate (e.g., condense) on the semiconductor wafer104.

Moisture that accumulates on the semiconductor wafer104may increase with a duration of time the semiconductor wafer104is within the environment120(e.g., while the semiconductor wafer104is staged within the transport carrier106stationed on the load port108and awaiting transfer and/or processing by the processing tool110). As such, and for longer staging periods, maintaining the relative humidity within the environment120so that moisture does not condense on the semiconductor wafer104may avoid corrosion on the semiconductor wafer104while the semiconductor wafer104is within the environment120and also prevent manufacturing defects by the processing tool110.

As shown inFIG.1B, the flow of the gas128from the gas curtain system126impedes the flow of the gas132through the opening122. To impede the flow of the gas132through the opening122, the flow of the gas128may include one or more properties. For example, the flow of the gas128may include an approximately laminar flow (e.g., include a flow corresponding to a Reynolds (Re) number of less than approximately 2300 or another value). Configuring the gas curtain system126to provide the approximately laminar flow may increase the effectiveness of the flow of the gas128blocking the flow of the gas132through the opening122by reducing turbulence in the flow of the gas128, for example.

As another example, the gas curtain system126may provide the flow of the gas128across the opening122at a flow rate that is in a range of approximately 325 liters per minute to approximately 375 liters per minute. As another example, the gas curtain system126may provide the flow of the gas128across the opening122at a pressure that is in a range of approximately 3 kilopascals to 5 kilopascals. Selecting respective properties of the flow of the gas128within one or more of these ranges may achieve a desired effectiveness of the flow of the gas128blocking the flow of the gas132through the opening122, reducing turbulence, and preventing contamination on the semiconductor wafer104. However, other values for the flow rate and the pressure are within the scope of the present disclosure.

The flow of the gas128across the opening122reduces a likelihood of the flow of the gas132from entering the transport carrier106and mixing with the flow of the gas146. In this way, the relative humidity of the environment120within the transport carrier106may be maintained to satisfy one or more thresholds. Maintaining the relative humidity to satisfy a threshold that is in a range of approximately 0.0% to approximately 0.5% may reduce a likelihood of corrosion forming on the semiconductor wafer104during processing of the semiconductor wafer104by the processing tool110.

FIG.1Cillustrates aspects of the controller130in communication with the gas curtain system126described herein. The controller130may communicate with one or more components of the gas curtain system126using one or more communication links150(e.g., one or more wireless-communication links, one or more wired-communication links, or a combination of one or more wireless-communication links and one or more wired-communication links).

Using the communication links150, the gas curtain system126may transmit one or more signals152or receive one or more signals154. The one or more signals152and154may include individual signals, combinations or sequences of signals, analog signals, digital signals, digital communications, voltages, resistances, currents, and/or other types of signals. The one or more signals152transmitted by the controller130may include, as examples, one or more indications to activate one or more components of the gas curtain system126, one or more indications to adjust settings of one or more components of the gas curtain system126, one or more indications to deactivate one or more components of the gas curtain system126, among other examples. The one or more signals154received by the controller130may include sensor data associated with a condition of an environment (e.g., the environment114or the environment120) and/or sensor data associated with a position or location of a component (e.g., a position or location of the door124or the semiconductor wafer104), among other examples.

The gas curtain system126may include a combination of one or more components, including a gas source component156(e.g., a gas supply system such as an XCDA system or an N2system) that supplies the mixture of gas used for the flow of the gas128and a gas distribution component158that provides the flow of the gas128across the opening122. In some implementations, the gas source component156includes a combination of valves and/or additional gas sources that allow the gas source component156to change a mixture of the flow of the gas128. In some implementations, and as shown inFIG.1C, the gas distribution component158includes a directional guide component160(e.g., a combination of one or more baffles, ports, rectifiers, and/or vents) that can change or adjust a direction of the flow of the gas128, among other examples.

The gas distribution component158may be located along an approximate edge162of the opening and be configured to provide the flow of the gas128in an approximately linear path across the opening122towards another approximate edge164that is opposite the approximate edge162. As described herein, the flow of the gas128may block another flow of a gas (e.g., the flow of the gas132originating from the FFU134and deflected towards the opening122by the aligner116) to impede moisture from accumulating on a semiconductor wafer positioned in a transport carrier (e.g., the semiconductor wafer104positioned in the transport carrier106) and reduce a likelihood of corrosion forming on the semiconductor wafer during processing of the semiconductor wafer by a processing tool (e.g., the processing tool110).

The gas curtain system126may include a combination of one or more sensors that provide sensor data (e.g., transmit sensor data using the one or more signals154) to the controller130. Based on the sensor data, the controller130may activate the gas curtain system126, deactivate the gas curtain system126, or adjust a setting of one or more components of the gas curtain system126, among other examples.

In some implementations, and as shown inFIG.1C, the combination of one or more sensors includes a door position sensor166(e.g., an interrupt sensor or a linear position sensor, among other examples) that is configured to detect a position of a door (e.g., the door124) or a transport carrier environment sensor168(e.g., a humidity sensor, a pressure sensor, or a thermocouple, among other examples) that is configured to detect one or more properties of an environment of a transport carrier (e.g., a relative humidity, a pressure, or temperature of the environment120of the transport carrier106, among other examples). Additionally and/or alternatively, the controller130may be configured to detect the position of the door based on sensor data received from the door position sensor166and/or may be configured to detect the one or more properties of the environment in the transport carrier based on sensor data received from the transport carrier environment sensor168.

The combination of one or more sensors may also include a chamber environment sensor170(e.g., a humidity sensor, a pressure sensor, or a thermocouple, among other examples) that is configured to detect one or more properties of a chamber (e.g., a relative humidity, a pressure, and/or a temperature of the environment114of the chamber112, among other examples), or a semiconductor wafer position sensor172(e.g., an interrupt sensor, a linear position sensor, or a rotary position sensor integrated into the transport tool118, among other examples) that is configured to detect a position of a semiconductor wafer (e.g., the semiconductor wafer104during a transfer operation). Additionally and/or alternatively, the controller130may be configured to detect the one or more properties of the chamber based on sensor data received from the chamber environment sensor170and/or may be configured to detect a position of the semiconductor wafer based on sensor data received from the semiconductor wafer position sensor172.

The gas curtain system126shown inFIG.1Cmay include a combination of one or more of a flow-rate component174(e.g., a valve or a fan, among other examples), a heater component176(e.g., a coil heater, among other examples), or a motor component178(e.g., a stepper motor or a servo motor, among other examples) that is mechanically coupled to the directional guide component160. The flow-rate component174may increase or reduce a rate of flow of the gas128. The heater component176may increase or decrease a temperature of the flow of the gas128. The motor component178may change or adjust an orientation of baffles or ports within the directional guide component160to cause a change or an adjustment in a direction of the flow of the gas128.

The controller130may be configured to transmit one or more indications in or using one or more of the signals152to the combination of the one or more components of the gas curtain system126to change one or more properties of the flow of the gas128based on sensor data received using the one or more signals154.

For example, the controller130may be configured receive sensor data from the door position sensor166and determine, based on the sensor data, that a door of a transport carrier (e.g., the door124of the transport carrier106) is in an open position and transmit, based on determining that the door of the transport carrier is in the open position, an indication to activate the gas curtain system126(e.g., open a port or valve of the gas source component156, among other examples). Conversely, if the controller130determines that the door of the transport carrier is in a closed position, the controller130may transmit an indication to deactivate the gas curtain system126.

As another example, the controller130may be configured to receive, from the transport carrier environment sensor168, sensor data associated with a relative humidity of an environment within a transport carrier (e.g., the environment120within the transport carrier106). The controller130may also be configured to receive, from the chamber environment sensor170, sensor data associated with a relative humidity of an environment within a chamber (e.g., the environment114within the chamber112). The controller130may be configured to determine to adjust a setting of one or more components of the gas curtain system126and transmit, based on determining to adjust the setting of one or more components of the gas curtain system126, an indication to cause an adjustment to the setting of the one or more components. In some implementations, the controller130determining to adjust the setting is based on the sensor data associated with the relative humidity of the environment in the transport carrier and the sensor data associated with the relative humidity of the environment within the chamber (e.g., the relative humidity of the environment114within the chamber112being greater than the relative humidity of the environment120within the transport carrier106). The indication to cause the adjustment of the one or more components may include an indication that causes an adjustment to a setting of the flow-rate component174to increase or decrease a velocity of the flow of the gas128, an indication to cause an adjustment to a setting of the heater component176to increase or decrease a temperature of the flow of the gas128, or an indication to cause an adjustment to a setting of the motor component178that changes angular positions of baffles within the directional guide component160to change a direction of the flow of the gas128, among other examples. The adjustment to the one or more components may generate a high velocity, high temperature flow of the gas128to increase resistance to a high moisture content gas (e.g., the flow of the gas132) and, for any portion of the high moisture content gas that may enter the opening122, mix with the portion to dilute or lessen moisture content.

As another example, the controller130is configured to determine, based on sensor data from the transport carrier environment sensor168and the chamber environment sensor170, that a difference in a relative humidity of each respective environment does not satisfy a threshold (e.g., the difference is approximately equal to or less than the threshold). In such an implementation, the controller130refrains from sending an indication to activate the gas curtain system126or to adjust a setting of one or more components of the gas curtain system126.

Another example includes the controller130being configured to receive, from the semiconductor wafer position sensor172, sensor data associated with a location of a wafer (e.g., a location of the semiconductor wafer104during a transfer operation). In some implementations, the semiconductor wafer position sensor172may be included as part of a transport tool (e.g., the transport tool118).

The controller130may be configured to determine, based on the sensor data associated with the location of the semiconductor wafer, to adjust a setting of one or more components of the gas curtain system126. The controller130may be further configured, based on determining to adjust the setting of one or more components, to transmit an indication to cause an adjustment to the setting of the one or more components. As an example, the controller130may determine that the semiconductor wafer is co-located with the flow of the gas128(e.g., in or passing through the opening122) and transmit an indication to cause an adjustment to a setting of the flow-rate component174to reduce a velocity of the flow of the gas128, an indication to cause an adjustment to a setting of the gas source component156to change a mix of the flow of the gas128, or an indication to cause an adjustment to a setting of the heater component176to alter a temperature of the flow of the gas128. In this example instance, the adjustment to the one or more components may create a low velocity, low moisture content, and high temperature flow of the gas128to heat the semiconductor wafer and evaporate condensed moisture from surfaces of the semiconductor wafer as the semiconductor wafer passes through the opening122.

Another example includes the controller130being configured to receive sensor data from one or more sensors of the gas curtain system126(e.g., one or more of the door position sensor166, the transport carrier environment sensor168, the chamber environment sensor170, or the semiconductor wafer position sensor172). Based on the sensor data, the controller130may determine a correlation between a relative humidity of an environment within a transport carrier (e.g., a relative humidity of the environment120of the transport carrier106) and one or more settings of one or more components of the gas curtain system126(e.g., one or more settings of one or more of the gas source component156, the flow-rate component174, the heater component176, or the motor component178, among other examples). The controller130may provide information relating to the correlation to update a machine-learning model that the controller130uses to estimate the relative humidity of the environment within the transport carrier for different settings of the one or more other components of the gas curtain system126.

For a combination of operating conditions and/or parameters, the controller130may use the machine-learning model to estimate, based on environmental and/or gas flow conditions within a transport carrier (e.g., the transport carrier106) or a chamber (e.g., the chamber112), settings for one or more components of the gas curtain system126that prevent moisture condensation on a semiconductor wafer (e.g., the semiconductor wafer104) within the transport carrier and/or corrosion during processing of the semiconductor wafer by a processing tool (e.g., the processing tool110). The controller130may further use the machine-learning model to determine estimated probabilities (e.g., risk scores) for the moisture condensation and/or corrosion based on the settings of the one or more components and environmental conditions within a semiconductor processing environment (e.g., the semiconductor processing environment100, including the environment114of the chamber112and the environment120of the transport carrier106), properties of one or more gases within the semiconductor processing environment (e.g., the flow of the gas128from the gas curtain system126, the flow of the gas132deflected by the aligner116, or the flow of the gas146within the transport carrier106), and/or a type of material layer on a semiconductor wafer (e.g., the semiconductor wafer104) based on a production schedule, among other examples. Thus, the machine-learning model may be updated to improve an output of the machine-learning model.

As indicated above,FIGS.1A-1Care provided as examples. Other examples may differ from what is described with regard toFIGS.1A-1C. For example, another example may include additional components, fewer components, different components, or differently arranged components than those shown inFIGS.1A-1C. Additionally, or alternatively, a set of components (e.g., one or more components) ofFIGS.1A-1Cmay perform one or more functions described herein as being performed by another set of components.

InFIG.2A, example202-1shows the flow of the gas132entering the transport carrier106through the opening122and mixing with the flow of the gas146provided by the gas system144. Due to a high moisture content of the flow of the gas132(e.g., the relatively high moisture content142), a relative humidity of the environment120within the transport carrier106does not satisfy a threshold204-1. As an example, the threshold may correspond to a relative humidity of approximately 0.5% (e.g., not satisfying the threshold corresponds to the relative humidity within the environment120being greater than or equal approximately 0.5%).

The threshold204-1may apply to one or more implementations of the semiconductor wafer104in different sub-regions within the transport carrier106. For instance, the threshold204-1may apply to a semiconductor wafer104-1in a twenty-fourth slot of the transport carrier106, a semiconductor wafer104-2in a thirteenth slot of the transport carrier106, and a semiconductor wafer104-3in a first slot of the transport carrier106.

In some implementations, and as shown inFIG.2A, the transport carrier106includes a configuration that includes a diffuser206through which the flow of the gas146enters the transport carrier106and an outlet port208through which the flow of the gas146exits the transport carrier. This type of transport carrier106may be referred to as a “snorkel FOUP” or another type of FOUP that includes a diffuser206(e.g., a “snorkel”).

Turning toFIG.2B, example202-2shows the flow of the gas128(e.g., the flow of the gas128from the gas curtain system126) blocking the flow of the gas132from entering the transport carrier106through the opening122. As a result, a relative humidity of the environment120within the transport carrier106may be maintained to satisfy a threshold204-2. As an example, the threshold may correspond to a relative humidity of approximately 0.0% to approximately 0.5% (e.g., satisfying the threshold corresponds to the relative humidity within the environment120being in a range from approximately 0.0% to approximately 0.5%). Maintaining the relative humidity to satisfy such a threshold may minimize or reduce a likelihood of corrosion on the semiconductor wafer104during a subsequent processing step (e.g., a deposition step performed by the processing tool110). However, other values for the relative humidity are within the scope of the present disclosure.

The threshold204-2may apply to one or more instances of the semiconductor wafer104in different sub-regions within the transport carrier106. For instance, the threshold204-2may apply to the semiconductor wafer104-1in the twenty-fourth slot of the transport carrier106, the semiconductor wafer104-2in the thirteenth slot of the transport carrier106, and the semiconductor wafer104-3in the first slot of the transport carrier106.

In the context ofFIGS.2A and2B, and in some implementations, the transport carrier106may be positioned on a load port (e.g., the load port108) adjacent to a chamber (e.g., the chamber112) of an interface tool (e.g., the interface tool102), and a controller (e.g., the controller130) may determine that one or more parameters associated with the environment120(e.g., a first environment) within the transport carrier106do not satisfy the threshold204-2. Based on determining that the one or more parameters do not satisfy the threshold204-2, the controller may determine one or more adjusted settings for a gas curtain system (e.g., the gas curtain system126) included in the interface tool.

The controller may transmit an indication (e.g., the signal152including an indication) of the one or more adjusted settings to cause one or more properties of the flow of the gas128(e.g., a first flow of a first gas) from the gas curtain system across an opening between environment120within the transport carrier and an environment within the chamber (e.g., a second environment corresponding to the environment114in the chamber112) to be adjusted such that the one or more parameters satisfy the threshold204-2. In doing so, the flow of the gas128from the gas curtain system may impede a flow of another gas (e.g., a second flow of a second gas corresponding to the flow of the gas132) from transferring from the second environment within the chamber to the first environment within the transport carrier to prevent an increase in humidity in the first environment within the transport carrier.

As indicated above,FIGS.2A and2Bare provided as examples. Other examples may differ from what is described with regard toFIGS.2A and2B.

FIGS.3A-3Fare diagrams of an example implementation300described herein. The example implementation300includes an example of transferring a semiconductor wafer104between the load port108and the processing tool110(e.g., a chemical vapor deposition (CVD) processing tool, a physical vapor deposition (PVD) processing tool, or a photolithography processing tool, among other examples). The example implementation300includes one or more processes performed by an interface tool (e.g., the interface tool102) including a gas curtain system (e.g., the gas curtain system126).

As described herein, the example implementation300may include the interface tool determining that a door (e.g., the door124) of a transport carrier (e.g., the transport carrier106) has been opened, where the transport carrier is located on a load port (e.g., the load port108) and interfaced with an opening (e.g., the opening122) in a side of a chamber (e.g., the chamber112) of the interface tool. In the example implementation300, a first gas (e.g., the flow of the gas146) provided by a first gas system (e.g., the first gas system144) has a first amount of moisture content (e.g., the relatively low moisture content148) and circulates within the transport carrier.

The example implementation300further includes providing, by a second gas system (e.g., the gas curtain system126) of the interface tool based on determining that the door of the transport carrier has been opened, a second gas (e.g., the flow of the gas128) across the opening. In some implementations, the second gas originates along a first approximate edge (e.g., the approximate edge162) of the opening and flows across the opening in an approximately linear path towards a second approximate edge (e.g., the approximate edge164) of the opening that is opposite the first approximate edge. The flow of the gas may reduce a likelihood of a third gas flowing within the chamber of the interface tool (e.g., the flow of the gas132within the chamber112of the interface tool102) and having a second amount of moisture content that is greater than the first amount of moisture content (e.g., the relatively high moisture content142that is greater than the relatively low moisture content148) from entering the transport carrier and mixing with the first gas so that a relative humidity of an environment (e.g., a relative humidity of the environment120) satisfies a threshold (e.g., the threshold204-2).

Turning toFIG.3A, the controller130may perform a process302corresponding to an initialization process. As shown inFIG.3A, the transport carrier106including the semiconductor wafer104is located on the load port108. The flow of the gas146(e.g., the flow of the gas146having the relatively low moisture content148) circulates within the transport carrier106. Within the chamber112, the aligner116deflects the flow of the gas132(e.g., the flow of the gas132having the relatively high moisture content) towards the door124of the transport carrier.

As shown inFIG.3B, the controller130performs a process304that includes receiving sensor data from the door position sensor166. Based on the data, the controller130determines that the door124is in an open position. The process304may further include, as shown inFIG.3B, the controller130receiving sensor data from the transport carrier environment sensor168and determining that a relative humidity of the environment120satisfies a threshold (e.g., is approximately equal to or greater than the threshold). The sensor data from the door position sensor166and/or the sensor data from the transport carrier environment sensor168is received by the controller130using the one or more communication links150.

Based on one or more determinations made at process304, and as part of process306shown inFIG.3C, the controller130may communicate with one or more components of the gas curtain system126to activate the gas curtain system126and provide the flow of the gas128across the opening122and to block the flow of the gas132from entering the opening122. Activating the gas curtain system126in process306may include, for example, the controller130transmitting an indication (e.g., the signal152including an indication) to adjust a setting of one or more of the gas source component156, the flow-rate component174, the heater component176, or the motor component178such that the flow of the gas128includes certain properties (e.g., a flow having a velocity, a flow having a flow rate, or a mixture having a temperature, a cleanliness, or an amount of oxygen content, among other examples). In this example, the properties may include a high velocity flow of the gas128to increase resistance to the flow of the gas132entering the opening122and mixing with the flow of the gas146.

Turning toFIG.3D, the controller130may perform a process308that changes properties of the flow of the gas128during a transfer of the semiconductor wafer104by the transport tool118(e.g., as shown inFIG.3D, the transport tool118is retrieving the semiconductor wafer104from the transport carrier106to transfer the semiconductor wafer104to the processing tool110).

During the retrieval of the wafer, the controller130may perform the process308that includes receiving sensor data from the semiconductor wafer position sensor172and, based on the sensor data, determining that the semiconductor wafer104is passing through the opening122(e.g., a location of the semiconductor wafer104). Based on determining that the semiconductor wafer104is passing through the opening122, and as part of the process308, the controller130may further transmit an indication (e.g., the signal152including an indication) to adjust a setting of one or more of the gas source component156, the flow-rate component174, the heater component176, or the motor component178such that the flow of the gas128includes certain properties (e.g., a flow having a velocity, a flow having a flow rate, or a mixture having a temperature, a cleanliness, or an amount of oxygen content, among other examples). In this example, the properties may include a high temperature flow of the gas128to heat the semiconductor wafer104and evaporate condensed moisture from surfaces of the semiconductor wafer104as the semiconductor wafer104passes through the opening122.

FIG.3Eshows the transport tool118completing the transfer of the semiconductor wafer from the transport carrier106to the processing tool110. InFIG.3E, and as part of a process310, the controller130may receive sensor data from the semiconductor wafer position sensor172and, based on the sensor data, determine that that the transfer is complete. Based on determining that the transfer is complete, and as part of the process310, the controller130may further transmit an indication (e.g., the signal152including an indication) to adjust a setting of one or more of the gas source component156, the flow-rate component174, the heater component176, or the motor component178such that the flow of the gas128includes certain properties (e.g., a flow having a velocity, a flow having a flow rate, or a mixture having a temperature, a cleanliness, or an amount of oxygen content, among other examples). In this example, the properties may include a high velocity flow of the gas128to increase resistance to the flow of the gas132entering the opening122and mixing with the flow of the gas146.

As shown inFIG.3F, the transport tool118has completed transferring one or more of the semiconductor wafers104from the transport carrier106to the processing tool110. InFIG.3F, and as part of a process312, the controller130receives sensor data from the door position sensor166. Based on the data, the controller130determines that the door124is in a closed position.

The process312may further include the controller130determining, based on the closed position of the door124, to deactivate the gas curtain system126. To deactivate the gas curtain system126, the controller130may transmit an indication (e.g., the signal152including an indication) to adjust a setting of one or more of the gas source component156, the flow-rate component174, the heater component176, or the motor component178such that the flow of the gas128is stopped.

As indicated above,FIGS.3A-3Fare provided as examples Other examples may differ from what is described with regard toFIGS.3A-3F. For example, another example may include additional components, fewer components, different components, or differently arranged components than those shown inFIGS.3A-3F. Additionally, or alternatively, a set of components (e.g., one or more components) ofFIGS.3A-3Fmay perform one or more functions described herein as being performed by another set of components.

FIGS.4A-4Eare diagrams of an example implementation400described herein.FIGS.4A-4Eshow structures, layers, and/or other components associated with an electronic device (e.g., an integrated circuit device, a semiconductor device) manufactured on a semiconductor wafer104during processing in the semiconductor processing environment100ofFIGS.1A-1C. Within the semiconductor processing environment100, the semiconductor wafer104may be transported using a transport carrier (e.g., the transport carrier106) and stationed on a load port (e.g., the load port108). As part of manufacturing the device, an interface tool (e.g., the interface tool102) may transfer the semiconductor wafer104to one or more processing tools (e.g., the processing tool110), such as a deposition tool.

As shown inFIG.4A, the device on the semiconductor wafer104includes multiple structures that are manufactured as part of a device on a substrate402. Through a combination of semiconductor manufacturing steps that may include chemical mechanical polishing/planarization (CMP), photolithography, and etching (e.g., dry etching and/or wet etching), the device may be manufactured to include a metal gate structure404, sidewall spacers405, a metal gate (MG) cap406, and a self-aligned contact (SAC) capping layer407. The device may also include a metal source/drain contact (MD) structure408that is electrically connected to a source/drain region409and an etch stop layer (ESL)410.

In some implementations, the metal gate structure404includes a metal material, a high-k material, and/or another suitable material. The metal gate structure404includes a conductive metallic material (or metal alloy) such as cobalt (Co), tungsten (W), ruthenium (Ru), molybdenum (Mo), titanium (Ti), titanium nitride (TiN), another metallic material, and/or a combination thereof. The sidewall spacers405are included to electrically isolate the metal gate structure404from adjacent conductive structures included on the device, and thus may be referred to as gate spacers. The sidewall spacers405include a silicon oxide (SiOx), a silicon nitride (SiXNy), a silicon oxy carbide (SiOC), a silicon oxycarbonitride (SiOCN), and/or another suitable material.

In some implementations, the MG cap406is included to protect the metal gate structure404from oxidization and/or etch damage during processing of the device, which preserves the low contact resistance of the metal gate structure404. The MG cap406may include a conductive metallic material (or metal alloy) such as cobalt (Co), tungsten (W), ruthenium (Ru), molybdenum (Mo), titanium (Ti), titanium nitride (TiN), another metallic material, and/or a combination thereof. The dielectric capping layer218includes a dielectric material such as a lanthanum oxide (LaxOy), an aluminum oxide (AlxOy), a yttrium oxide (YxOy), a tantalum carbon nitride (TaCN), a zirconium silicide (ZrSix), a silicon oxycarbonitride (SiOCN), a silicon oxycarbide (SiOC), a silicon carbon nitride (SiCN), a zirconium nitride (ZrN), a zirconium aluminum oxide (ZrAlO), a titanium oxide (TixOy), a tantalum oxide (TaxOy), a zirconium oxide (ZrxOy), a hafnium oxide (HfxOy), a silicon nitride (SixNy), a hafnium silicide (HfSix), an aluminum oxynitride (AlON), a silicon oxide (SixOy), a silicon carbide (SiC), and/or a zinc oxide (ZnxOy), among other examples.

The SAC capping layer407protects the metal gate structure404from processing damage during processing of the device. In some implementations, the SAC capping layer407includes a dieletric material such as a lanthanum oxide (LaxOy), an aluminum oxide (AlxOy), a yttrium oxide (YxOy), a tantalum carbon nitride (TaCN), a zirconium silicide (ZrSix), a silicon oxycarbonitride (SiOCN), a silicon oxycarbide (SiOC), a silicon carbon nitride (SiCN), a zirconium nitride (ZrN), a zirconium aluminum oxide (ZrAlO), a titanium oxide (TixOy), a tantalum oxide (TaxOy), a zirconium oxide (ZrxOy), a hafnium oxide (HfxOy), a silicon nitride (SixNy), a hafnium silicide (HfSix), an aluminum oxynitride (AlON), a silicon oxide (SixOy), a silicon carbide (SiC), and/or a zinc oxide (ZnxOy), among other examples.

In some implementations the MD structure408includes a metal material (e.g., cobalt, ruthenium, or copper, among other examples). Furthermore, and as shown inFIG.4A, the device includes a gate interconnect structure412that passes through a dielectric layer414.

Turning toFIG.4B, additional manufacturing steps (e.g., photolithography manufacturing steps, dry etching manufacturing steps, wet cleaning steps, among other examples) form an opening416in the dielectric layer414and in the ESL410. In some implementations, the opening416is formed in preparation for forming a metal source/drain interconnect structure in the opening416to the MD structure408.

FIG.4Cshows the device in preparation for a deposition process. Within the opening416, a surface of the MD structure408may be exposed. During a deposition process by a processing tool, (e.g., a physical vapor deposition (PVD) process or a chemical vapor deposition process by the processing tool110ofFIGS.1A-1C), moisture on the exposed surface of the MD structure408may cause corrosion. Accordingly, the gas curtain system126described herein may maintain a relative low humidity of an environment within a transport carrier containing the semiconductor wafer104(e.g., maintain the relative low humidity of the environment120of the transport carrier106containing the semiconductor wafer104) to prevent moisture from condensing on the exposed surface of the MD structure408prior to the semiconductor wafer being transferred from the transport carrier to the processing tool. In this way, the corrosion may be prevented (or the likelihood of the corrosion occurring may be reduced or minimized).

FIG.4Dshows the device after deposition manufacturing processes and without corrosion. As shown, the device includes a metal source/drain interconnect structure418that is formed through the dielectric layer414and the etch stop layer410. In some implementations, and as shown inFIG.4D, the device includes a metal cap420.

FIG.4Eshows an alternative embodiment toFIG.4Din which the metal cap420is omitted from the device. Here, the metal source/drain interconnect structure418is in direct contact with the MD structure408.

As indicated above,FIGS.4A-4Eare provided as examples. Other examples may differ from what is described with regard toFIGS.4A-4E. For example, another example may include additional structures, fewer structures, different structures or differently arranged structures than those shown inFIGS.4A-4E. Additionally, or one or more semiconductor wafer manufacturing processes or devices other than those described inFIGS.4A-4Emay receive the benefits of a gas curtain system (e.g., the gas curtain system126).

FIG.5is a diagram of example components of one or more devices ofFIGS.1A-1C.FIG.5includes example device500, which may correspond to the interface tool102, the transport carrier106, the load port108, the processing tool110, the transport tool118, the gas curtain system126, and/or the controller130. In some implementations, the interface tool102, the transport carrier106, the load port108, the processing tool110, the transport tool118, the gas curtain system126, and/or the controller130may include one or more devices500and/or one or more components of device500. As shown inFIG.5, device500may include a bus510, a processor520, a memory530, an input component540, an output component550, and a communication component560.

Bus510includes one or more components that enable wired and/or wireless communication among the components of device500. Bus510may couple together two or more components ofFIG.5, such as via operative coupling, communicative coupling, electronic coupling, and/or electric coupling. Processor520includes a central processing unit, a graphics processing unit, a microprocessor, a controller, a microcontroller, a digital signal processor, a field-programmable gate array, an application-specific integrated circuit, and/or another type of processing component. Processor520is implemented in hardware, firmware, or a combination of hardware and software. In some implementations, processor520includes one or more processors capable of being programmed to perform one or more operations or processes described elsewhere herein.

Memory530includes volatile and/or nonvolatile memory. For example, memory530may include random access memory (RAM), read only memory (ROM), a hard disk drive, and/or another type of memory (e.g., a flash memory, a magnetic memory, and/or an optical memory). Memory530may include internal memory (e.g., RAM, ROM, or a hard disk drive) and/or removable memory (e.g., removable via a universal serial bus connection). Memory530may be a non-transitory computer-readable medium. Memory530stores information, instructions, and/or software (e.g., one or more software applications) related to the operation of device500. In some implementations, memory530includes one or more memories that are coupled to one or more processors (e.g., processor520), such as via bus510.

Input component540enables device500to receive input, such as user input and/or sensed input. For example, input component540may include a touch screen, a keyboard, a keypad, a mouse, a button, a microphone, a switch, a sensor, a global positioning system sensor, an accelerometer, a gyroscope, and/or an actuator. Output component550enables device500to provide output, such as via a display, a speaker, and/or a light-emitting diode. Communication component560enables device500to communicate with other devices via a wired connection and/or a wireless connection. For example, communication component560may include a receiver, a transmitter, a transceiver, a modem, a network interface card, and/or an antenna.

Device500may perform one or more operations or processes described herein. For example, a non-transitory computer-readable medium (e.g., memory530) may store a set of instructions (e.g., one or more instructions or code) for execution by processor520. Processor520may execute the set of instructions to perform one or more operations or processes described herein. In some implementations, execution of the set of instructions, by one or more processors520, causes the one or more processors520and/or the device500to perform one or more operations or processes described herein. In some implementations, hardwired circuitry may be used instead of or in combination with the instructions to perform one or more operations or processes described herein. Additionally, or alternatively, processor520may be configured to perform one or more operations or processes described herein. Thus, implementations described herein are not limited to any specific combination of hardware circuitry and software.

The number and arrangement of components shown inFIG.5are provided as an example. Device500may include additional components, fewer components, different components, or differently arranged components than those shown inFIG.5. Additionally, or alternatively, a set of components (e.g., one or more components) of device500may perform one or more functions described as being performed by another set of components of device500.

FIG.6is a flowchart of an example process600relating to operating the gas curtain system126described herein. In some implementations, one or more process blocks ofFIG.6are performed by a controller (e.g., the controller130) and/or a gas curtain system (e.g., gas curtain system126). In some implementations, one or more process blocks ofFIG.6are performed by another device or a group of devices separate from or including the controller130and/or the gas curtain system126, such as the interface tool102, the transport carrier106, the load port108, the processing tool110, or the transport tool118. Additionally, or alternatively, one or more process blocks ofFIG.6may be performed by one or more components of device500, such as processor520, memory530, input component540, output component550, and/or communication component560.

As shown inFIG.6, process600may include determining that a door of a transport carrier has been opened (block610). For example, the controller130may determine that a door124of a transport carrier106has been opened. In some implementations, the transport carrier106is located on the load port108and interfaced with an opening122in a side of a chamber112of an interface tool102. In some implementations, a first gas (e.g., gas146) having a first amount of moisture content148and provided by a first gas system (e.g., gas system144) of the load port108circulates within the transport carrier106.

As further shown inFIG.6, process600may include providing, based on determining that the door of the transport carrier has been opened, a second gas across an opening (block620). For example, based on the controller130determining that the door124of the transport carrier106has been opened, the gas curtain system126may provide a second gas (e.g., gas128) across the opening122. In some implementations, the second gas originates along a first approximate edge162of the opening122and flows across the opening122in an approximately linear path towards a second approximate edge164of the opening122that is opposite the first approximate edge162, and reduces a likelihood of a third gas (e.g., gas132) flowing within an interface tool102and having a second amount of moisture content142that is greater than the first amount of moisture content148, from entering the transport carrier106and mixing with the first gas so that a relative humidity of an environment120within the transport carrier106satisfies a threshold204-2.

In a first implementation, the first gas or the second gas includes an extra clean dry air gas or a nitrogen gas.

In a second implementation, alone or in combination with the first implementation, the threshold is in a range of approximately 0.0% to approximately 0.5%.

In a third implementation, alone or in combination with one or more of the first and second implementations, the flow of the second gas is an approximately laminar flow.

In a fourth implementation, alone or in combination with one or more of the first through third implementations, a second gas system (e.g., gas system126) provides the second gas across the opening122at a flow rate that is in a range of approximately 325 liters per minute to approximately 375 liters per minute.

In a fifth implementation, alone or in combination with one or more of the first through fourth implementations, the second gas system provides the second gas across the opening122at pressure that is in a range of approximately 3 kilopascal to 5 kilopascal.

In a sixth implementation, alone or in combination with one or more of the first through fifth implementations, the second gas includes a total organic carbon content that is in a range of approximately 1 part per billion to approximately 10 parts per billion.

AlthoughFIG.6shows example blocks of process600, in some implementations, process600may include additional blocks, fewer blocks, different blocks, or differently arranged blocks than those depicted inFIG.6. Additionally, or alternatively, two or more of the blocks of process600may be performed in parallel.

FIG.7is a flowchart of an example process700relating to operating the gas curtain system126described herein. In some implementations, one or more process blocks ofFIG.7are performed by a controller (e.g., the controller130). In some implementations, one or more process blocks ofFIG.7are performed by another device or a group of devices separate from or including the controller130, such as the interface tool102, the transport carrier106, the load port108, the processing tool110, the transport tool118, or components of the gas curtain system126. Additionally, or alternatively, one or more process blocks ofFIG.7may be performed by one or more components of device500, such as processor520, memory530, input component540, output component550, and/or communication component560.

As shown inFIG.7, process700may include determining that one or more parameters associated with a first environment within a transport carrier do not satisfy a threshold (block710). For example, the controller130may determine that one or more parameters associated with a first environment120within a transport carrier106do not satisfy a threshold. In some implementations, the transport carrier106is positioned on a load port108adjacent to a chamber112of an interface tool102.

As further shown inFIG.7, process700may include determining, based on determining that the one or more parameters do not satisfy the threshold, one or more adjusted settings for a gas curtain system (block720). For example, the controller130may determine, based on determining that the one or more parameters do not satisfy the threshold, one or more adjusted settings for a gas curtain system126included in the interface tool102, as described above.

As further shown inFIG.7, process700may include transmitting an indication of the one or more adjusted settings to cause one or more properties of a first flow of a first gas from the gas curtain system across an opening between the first environment within the transport carrier and a second environment within the chamber to be adjusted such that the one or more parameters satisfy the threshold (block730). For example, the controller130may transmit an indication (e.g., the signal152including an indication) of the one or more adjusted settings to cause one or more properties of a first flow of a first gas (e.g., gas128) from the gas curtain system126across an opening122between the first environment120within the transport carrier and a second environment114within the chamber112to be adjusted such that the one or more parameters satisfy the threshold. In some implementations, the first flow of the first gas from the gas curtain system126impedes a second flow of a second gas (e.g., gas132) from transferring from the second environment114within the chamber112to the first environment120within the transport carrier106to prevent an increase in humidity in the first environment120within the transport carrier106.

In a first implementation, transmitting the indication of the one or more adjusted settings includes transmitting the indication to a gas source component156of the gas curtain system126to cause an adjustment to a setting for controlling a mixture of the first gas.

In a second implementation, alone or in combination with the first implementation, transmitting the indication of the one or more adjusted settings includes transmitting the indication to a flow-rate component174of the gas curtain system126to cause an adjustment to a setting for controlling a flow rate of the first gas.

In a third implementation, alone or in combination with one or more of the first and second implementations, transmitting the indication of the one or more adjusted settings includes transmitting the indication to a heater component176of the gas curtain system126to cause an adjustment to a setting for controlling a temperature of the first gas.

In a fourth implementation, alone or in combination with one or more of the first through third implementations, transmitting the indication of the one or more adjusted settings includes transmitting the indication to a motor component178of the gas curtain system126that is mechanically coupled to a directional guide component160of a gas distribution component158to cause an adjustment to a setting for controlling an angle or distribution profile of the first gas from the gas distribution component158across the opening122.

In a fifth implementation, alone or in combination with one or more of the first through fourth implementations, process700includes transmitting, by the controller130, an indication of one or more adjusted settings to cause a change to a velocity at which a transport tool118transports a semiconductor wafer104through the opening122and through the first flow of the first gas, where the transport tool118transports the semiconductor wafer104through the opening122and through the first flow of the first gas as part of a transfer process between the transport carrier106and a processing tool110.

In a sixth implementation, alone or in combination with one or more of the first through fifth implementations, process700includes transmitting, by the controller130, an indication (e.g., the signal152including an indication) to cause the interface tool102to output, to a user of the interface tool102, a notification indicating a status of the gas curtain system126.

AlthoughFIG.7shows example blocks of process700, in some implementations, process700may include additional blocks, fewer blocks, different blocks, or differently arranged blocks than those depicted inFIG.7. Additionally, or alternatively, two or more of the blocks of process700may be performed in parallel.

Some implementations described herein provide a gas curtain system. The gas curtain system includes various components to prevent a gas flowing within a chamber of an interface tool from flowing through an opening into a transport carrier adjacent to the interface tool. The gas curtain system may include a gas distribution component along an edge of the opening that generates a flow of another gas across the opening towards an opposite edge of the opening. In this way, the gas from the chamber is prevented from entering the transport carrier. By preventing the gas from the chamber from entering the transport carrier, a relative humidity within an environment of the transport carrier is maintained such that condensation of moisture on one or more semiconductor wafers within the transport carrier is mitigated. Subsequently, corrosion on the one or more semiconductor wafers during processing by a processing tool is prevented.

As described in greater detail above, some implementations described herein provide a method. The method includes determining, by an interface tool, that a door of a transport carrier has been opened, where the transport carrier is located on a load port and interfaced with an opening in a side of a chamber of the interface tool, and where a first gas having a first amount of moisture content and provided by a first gas system of the load port circulates within the transport carrier. The method includes providing, by a second gas system of the interface tool based on determining that the door of the transport carrier has been opened, a second gas across the opening, where the second gas: originates along a first approximate edge of the opening and flows across the opening in an approximately linear path towards a second approximate edge of the opening that is opposite the first approximate edge, and reduces a likelihood of a third gas, flowing within the chamber of the interface tool and having a second amount of moisture content that is greater than the first amount of moisture content, from entering the transport carrier and mixing with the first gas so that a relative humidity of an environment within the transport carrier satisfies a threshold.

As described in greater detail above, some implementations described herein provide an interface tool. The interface tool includes a load port configured to provide a first flow of a first gas through an inlet diffuser to a transport carrier positioned on the load port. The interface tool includes a chamber that has an opening, in a side of the chamber, configured to be orientated toward the transport carrier. The interface tool includes an aligner positioned within the chamber. The interface tool includes a fan filter unit. The interface tool includes a gas distribution component along an approximate edge of the opening that is configured to provide a second flow of a second gas across the opening, block a third flow of a third gas originating from the fan filter unit and deflected towards the opening by the aligner to: impede moisture from accumulating on a semiconductor wafer positioned in the transport carrier due to the third gas mixing with the first gas within the transport carrier, and reduce a likelihood of corrosion forming on the semiconductor wafer during processing of the semiconductor wafer by a processing tool configured to receive the semiconductor wafer from the interface tool..

As described in greater detail above, some implementations described herein provide a method. The method includes determining, by a controller, that one or more parameters associated with a first environment within a transport carrier do not satisfy a threshold, where the transport carrier is positioned on a load port adjacent to a chamber of an interface tool. The method includes determining, by the controller and based on determining that the one or more parameters do not satisfy the threshold, one or more adjusted settings for a gas curtain system included in the interface tool. The method includes transmitting, by the controller, an indication of the one or more adjusted settings to cause one or more properties of a first flow of a first gas from the gas curtain system across an opening between the first environment within the transport carrier and a second environment within the chamber to be adjusted such that the one or more parameters satisfy the threshold, where the first flow of the first gas from the gas curtain system impedes a second flow of a second gas from transferring from the second environment within the chamber to the first environment within the transport carrier to prevent an increase in humidity in the first environment within the transport carrier.