Process kit enclosure system

A process kit enclosure system includes surfaces to enclose an interior volume, a first support structure including first fins, a second support structure including second fins, and a front interface to interface the process kit enclosure system with a load port of a wafer processing system. The first and second fins are sized and spaced to hold process kit ring carriers and process kit rings in the interior volume. Each of the process kit rings is secured to one of the process kit ring carriers. The process kit enclosure system enables first automated transfer of a first process kit ring carrier securing a first process kit ring from the process kit enclosure system into the wafer processing system and second automated transfer of a second process kit ring carrier securing a second process kit ring from the wafer processing system into the process kit enclosure system.

TECHNICAL FIELD

Embodiments of the present disclosure relate to apparatuses and methods for process kit ring replacement in processing chambers, such as those used in wafer processing systems, and in particular to an enclosure for holding process kit rings.

BACKGROUND

In semiconductor processing and other electronics processing, platforms are often used that use robotic arms to transport objects such as wafers between processing chambers, from storage areas (e.g., front opening unified pods (FOUPs)) to processing chambers, from processing chambers to storage areas, and so on. A processing system, such as a wafer processing system, has one or more processing chambers for processing of substrates. A gas may be used to etch a substrate in a processing chamber (e.g., a substrate may be etched while electrostatically clamped in position in an etch chamber). One or more process kit rings may surround a substrate (e.g., to protect one or more portions of the processing chamber, the substrate, etc.). For example, a circular part, referred to as an edge ring or process kit ring, is positioned immediately outside of the outer diameter of the substrate to protect the upper surface of a chuck (e.g., an electrostatic chuck) supporting the substrate from being etched by etchant chemistry. Process kit rings are made from several different materials and can have different shapes, both which affect process uniformity near the process kit ring. During processing, process kit rings are etched over time and result in shape changes as well as changes in processing uniformity.

To address the changes in processing uniformity due to process kit ring deterioration, process kit rings are replaced according to a schedule. Conventionally, to replace a process kit ring, an operator opens a processing chamber to have access to the process kit ring inside, manually removes and replaces the process kit ring, and closes the processing chamber. While the processing chamber is open, the processing chamber and the processing system may become contaminated with cells, hair, dust, etc. The processing chamber and/or processing system then goes through a requalification process that may remove the processing chamber and/or processing system from operation for days to weeks. This impacts line yield, scheduling, quality (e.g., responsive to adding variables to the system), and so forth.

SUMMARY

In an aspect of the disclosure, a process kit enclosure system includes a plurality of surfaces to at least partially enclose an interior volume of the process kit enclosure system. The process kit enclosure system further includes a first support structure comprising a first plurality of approximately horizontal fins. The process kit enclosure system further includes a second support structure comprising a second plurality of approximately horizontal fins. The first plurality of approximately horizontal fins and the second plurality of approximately horizontal fins are sized and spaced to hold a plurality of process kit ring carriers and a plurality of process kit rings in the interior volume of the process kit enclosure system. Each of the plurality of process kit rings may be secured to one of the plurality of process kit ring carriers. The process kit enclosure system further includes a front interface coupled to one or more of the plurality of surfaces to interface the process kit enclosure system with a load port of a wafer processing system. The process kit enclosure system enables first automated transfer of a first process kit ring carrier securing a first process kit ring from the process kit enclosure system into the wafer processing system and second automated transfer of a second process kit ring carrier securing a second process kit ring from the wafer processing system into the process kit enclosure system.

In another aspect of the disclosure, a method includes interfacing a front interface of a process kit enclosure system with a load port of a wafer processing system. The process kit enclosure system includes a plurality of process kit ring carriers and a plurality of process kit rings in an interior volume of the process kit enclosure system. The interior volume is enclosed by a plurality of surfaces of the process kit enclosure system to which the front interface is coupled. Each of the plurality of process kit rings is secured to one of the plurality of process kit ring carriers. Each of the plurality of process kit ring carriers are placed on a corresponding first approximately horizontal fin of a first plurality of approximately horizontal fins of a first support structure and on a corresponding second approximately horizontal fin of a second plurality of approximately horizontal fins of a second support structure. The method further includes using a robot arm to perform automated transfer of first process kit ring carrier securing a first process kit ring from the process kit enclosure system from the process kit enclosure system into the wafer processing system. The method further includes using the robot arm or an additional robot arm to perform second automated transfer of a second process kit ring carrier securing a used second process kit ring from the wafer processing system into the process kit enclosure system.

In another aspect of the disclosure, a process kit enclosure system includes a plurality of surfaces to at least partially enclose an interior volume of the process kit enclosure system. The process kit enclosure system further includes a first support structure disposed within the interior volume. The process kit enclosure system further includes a second support structure disposed within the interior volume. The process kit enclosure system further includes an empty process kit ring carrier disposed on a first approximately horizontal fin of the first support structure and on a second approximately horizontal fin of the second support structure. The process kit enclosure system further includes a plurality of process kit ring carriers disposed on corresponding approximately horizontal fins of the first support structure and the second support structure. The plurality of process kit ring carriers may be are positioned above the empty process kit ring carrier in the process kit enclosure system. A corresponding process kit ring may be secured to each of the plurality of process kit ring carriers. The process kit enclosure system further includes placement validation wafer disposed on a third approximately horizontal fin of the first support structure and on a fourth approximately horizontal fin of the second support structure. The placement validation wafer is positioned above the plurality of process kit ring carriers in the process kit enclosure system.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments described herein are related to a process kit enclosure system. Process kit rings may surround substrates and/or portions of substrate support assemblies in a processing chamber to protect components (e.g., to protect the substrate support assembly) of the processing chamber. As the substrates are etched by etchant chemistry, the process kit rings may deteriorate over time. Deteriorated processing kit rings lead to processing non-uniformity (e.g., non-uniformity in processed substrates, non-uniformity in processes, etc.). To avoid non-uniformity, process kit rings are to be periodically replaced. Conventionally, to replace a process kit ring, the processing chamber is opened. After being opened, the processing chamber goes through a long requalification process. The requalification process impacts line yield, scheduling, quality, user time, energy used, and so forth.

The devices, systems, and methods disclosed herein use a process kit enclosure system (e.g., a front opening unified pod (FOUP) configured to contain one or more process kit rings) to enable automated replacement of process kit rings (e.g., without opening a process chamber). A process kit enclosure system may include surfaces to at least partially enclose an interior volume of the process kit enclosure system. For example, the process kit enclosure system may include sidewalls, a top cover, a bottom surface, and a door. The process kit enclosure system may include a front interface (e.g., door frame, etc.) to interface with a load port of a wafer processing system (e.g., a port of a factory interface). A door may be attached to the front interface of the process kit enclosure system for transportation and the door may be removed to engage the front interface with the load port. The process kit enclosure system may include a first support structure that includes first approximately horizontal fins and a second support structure that includes second approximately horizontal fins. The first approximately horizontal fins and the second approximately horizontal fins may be sized and spaced to hold contents such as one or more of a process kit ring, an empty process kit ring carrier, a process kit ring disposed on a process kit ring carrier, a placement validation wafer, etc. The process kit enclosure system may enable automated transfer of content (e.g., a new process kit ring secured on a process kit ring carrier, etc.) into the wafer processing system and automated transfer of content (e.g., a used process kit ring secured on a process kit ring carrier, etc.) from the wafer processing system into the process kit enclosure system.

The devices, systems, and methods disclosed herein have advantages over conventional solutions. The process kit enclosure system may interface with a load port of the wafer processing system and enable replacement of process kit rings without opening of a process chamber and without a subsequent requalification process of the process chamber. The load port may be configured to accept different types of enclosure systems, such as a front opening unified pod (FOUP). The load port may seal to the front interface of the process kit enclosure system to prevent contamination into the wafer processing system (factory interface) and to prevent harmful gases from exiting the wafer processing system (factory interface). The process kit enclosure system may include empty process kit ring carriers that a robot arm of the wafer processing system may use to remove a used process kit ring from the wafer processing system to place in the process kit enclosure system. The process kit enclosure system may include process kit rings that a robot arm may use to replace used process kit rings in the wafer processing system. The process kit enclosure system may include a placement validation wafer that the robot arm may use to verify placement of the process kit rings. The process kit enclosure system may enable removal of process kit rings, replacement of process kit rings, and verification of placement of the process kit rings without opening of any of the process chambers attached to the processing system and without undergoing the conventional requalification process for any process chamber. Use of the process kit enclosure system to replace process kit rings has less impact on line yield, scheduling, quality, user time, energy used, and so forth than conventional solutions.

FIG.1illustrates a processing system100(e.g., a wafer processing system), according to one aspect of the disclosure. The processing system100includes a factory interface101that includes multiple load ports128to which cassettes102(e.g., FOUPs) may be coupled for transferring wafers and/or other substrates into and out of the processing system100. The factory interface may also include a process kit enclosure system130(e.g., cassette, FOUP, etc.) coupled to a load port128for transferring content110such as process kit rings into and out of the processing system100.

A load port128may include a front interface that forms a vertical opening. The load port128may also have a horizontal surface. A FOUP may have a front interface that forms a vertical opening. The front interface of the FOUP may be sized to interface with the front interface of the load port128(e.g., the vertical opening of the FOUP may be approximately the same size as the vertical opening of the load port128). The FOUP may be placed on the horizontal surface of the load port128and the vertical opening of the FOUP may align with the vertical opening of the load port128. The front interface of the FOUP may interconnect with (e.g., clamp to, be secured to, be sealed to) the front interface of the load port128. A bottom plate (e.g., base plate) of the FOUP may have features (e.g., load features, such as recesses, that engage with load port kinematic pin features, a load port datum pin clearance, and/or a FOUP docking tray latch clamping feature) that engage with the horizontal surface of the load port128. The process kit enclosure system130has a front interface that is also sized to interface with the front interface of the load port128. The process kit enclosure system130may be placed on the horizontal surface of the load port128and the vertical opening of the process kit enclosure system130may align with the vertical opening of the load port128. The front interface of the process kit enclosure system130may interconnect with the front interface of the load port128. The process kit enclosure system130has a base plate that has features to engage with the horizontal surface of the load port128. The process kit enclosure system130may interface with the same load ports128that are used for FOUPs and cassettes that contain wafers.

The process kit enclosure system130may include one or more items of content110(e.g., one or more of a process kit ring, an empty process kit ring carrier, a process kit ring disposed on a process kit ring carrier, a placement validation wafer, etc.). For example, the process kit enclosure system130may be coupled to the factory interface101(e.g., load port128) to enable automated transfer of a process kit ring on a process kit ring carrier into the processing system100for replacement of a used process kit ring.

The processing system100may also include first vacuum ports103a,103bcoupling the factory interface101to respective degassing chambers104a,104b. Second vacuum ports105a,105bmay be coupled to respective degassing chambers104a,104band disposed between the degassing chambers104a,104band a transfer chamber106to facilitate transfer of wafers and content110(e.g., process kit rings) into the transfer chamber106. In some embodiments, a processing system100includes and/or uses one or more degassing chambers104and a corresponding number of vacuum ports103,105(e.g., a processing system100may include a single degassing chamber104, a single first vacuum port103, and a single second vacuum port105). The transfer chamber106includes a plurality of processing chambers107(e.g., four processing chambers107, six processing chambers, etc.) disposed therearound and coupled thereto. The processing chambers107are coupled to the transfer chamber106through respective ports108, such as slit valves or the like. In some embodiments, the factory interface101is at a higher pressure (e.g., atmospheric pressure) and the transfer chamber106is at a lower pressure. Each degassing chamber104(e.g., load lock, pressure chamber) may have a first door (e.g., first vacuum port103) to seal the degassing chamber104from the factory interface101and a second door (e.g., second vacuum port105) to seal the degassing chamber104from the transfer chamber106. Content may be transferred from the factory interface101into a degassing chamber104while the first door is open and the second door is closed, the first door may close, the pressure in the degassing chamber104may reduce to match the transfer chamber106, the second door may open, and the content may be transferred out of the degassing chamber104. A local center finding (LCF) device may be used to align the content in the transfer chamber106(e.g., before entering a processing chamber107, after leaving the processing chamber107).

The processing chambers107may include or more of etch chambers, deposition chambers (including atomic layer deposition, chemical vapor deposition, physical vapor deposition, or plasma enhanced versions thereof), anneal chambers, and the like. Some of the processing chambers107, such as etch chambers, may include process kit rings (e.g., edge ring, processing ring, support ring, sliding ring, quartz ring, etc.) therein, which occasionally are to be replaced. While conventional systems are associated with disassembly of a processing chamber by an operator to replace a process kit ring, the processing system100is configured to facilitate replacement of process kit rings without disassembly of a processing chamber107by an operator.

Factory interface101includes a factory interface robot111. Factory interface robot111may include a robot arm, and may be or include a selective compliance assembly robot arm (SCARA) robot, such as a 2 link SCARA robot, a 3 link SCARA robot, a 4 link SCARA robot, and so on. The factory interface robot111may include an end effector on an end of the robot arm. The end effector may be configured to pick up and handle specific objects, such as wafers. Alternatively, the end effector may be configured to handle objects such as process kit rings (edge rings). The factory interface robot111may be configured to transfer objects between cassettes102(e.g., FOUPs) and degassing chambers104a,104b.

Transfer chamber106includes a transfer chamber robot112. Transfer chamber robot112may include a robot arm with an end effector at an end of the robot arm. The end effector may be configured to handle particular objects, such as wafers. The transfer chamber robot112may be a SCARA robot, but may have fewer links and/or fewer degrees of freedom than the factory interface robot111in some embodiments.

A controller109controls various aspects of the processing system100. The controller109may be and/or include a computing device such as a personal computer, a server computer, a programmable logic controller (PLC), a microcontroller, and so on. The controller109may include one or more processing devices, which may be general-purpose processing devices such as a microprocessor, central processing unit, or the like. More particularly, the processing device may be a complex instruction set computing (CISC) microprocessor, reduced instruction set computing (RISC) microprocessor, very long instruction word (VLIW) microprocessor, or a processor implementing other instruction sets or processors implementing a combination of instruction sets. The processing device may also be one or more special-purpose processing devices such as an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a digital signal processor (DSP), network processor, or the like. The controller109may include a data storage device (e.g., one or more disk drives and/or solid state drives), a main memory, a static memory, a network interface, and/or other components. The controller109may execute instructions to perform any one or more of the methods or processes described herein. The instructions may be stored on a computer readable storage medium, which may include the main memory, static memory, secondary storage and/or processing device (during execution of the instructions). The controller109may receive signals from and send controls to factory interface robot111and wafer transfer chamber robot112in embodiments.

FIG.1schematically illustrates transfer of content110(e.g., a process kit ring coupled to a process kit ring carrier) into a processing chamber107. According to one aspect of the disclosure, content110is removed from a process kit enclosure system130via factory interface robot111located in the factory interface101. The factory interface robot111transfers the content110through one of the first vacuum ports103a,103band into a respective degassing chamber104a,104b. A transfer chamber robot112located in the transfer chamber106removes the content110from one of the degassing chambers104a,104bthrough a second vacuum port105aor105b. The transfer chamber robot112moves the content110into the transfer chamber106, where the content110may be transferred to a processing chamber107though a respective port108. While not shown for clarity inFIG.1, transfer of the content110may include transfer of a process kit ring disposed on a process kit ring carrier, transfer of an empty process kit ring carrier, transfer of a placement validation wafer, etc.

FIG.1illustrates one example of transfer of content110, however, other examples are also contemplated. For example, it is contemplated that the process kit enclosure system130may be coupled to the transfer chamber106(e.g., via a load port in the transfer chamber106). From the transfer chamber106, the content110may be loaded into a processing chamber107by the transfer chamber robot112. Additionally, content110may be loaded in a substrate support pedestal (SSP). An additional SSP may be positioned in communication with the factory interface101opposite the illustrated SSP. It is contemplated that a processed content110(e.g., a used process kit ring) may be removed from the processing system100in reverse of any manner described herein. When utilizing multiple process kit enclosure systems130or a combination of process kit enclosure system130and SSP, it is contemplated that one SSP or process kit enclosure system130may be used for unprocessed content110(e.g., new process kit rings), while another SSP or process kit enclosure system130may be used for receiving processed content110(e.g., used process kit rings).

In some embodiments, a process kit ring that is secured to an upper surface of a process kit ring carrier may be stored in the process kit enclosure system130and factory interface robot111may insert an end effector of the factory interface robot111into the process kit enclosure system130below the process kit ring carrier, lift the process kit ring carrier, and extract from the process kit enclosure system130to transport the process kit ring secured to the process kit ring carrier on the robot within the processing system100. In some embodiments, a process kit ring is stored within the process kit enclosure system130(e.g., without being secured to a process kit ring carrier). Factory interface robot111may obtain an empty process kit ring carrier from within the processing system100or the process kit enclosure system130and may use the empty process kit ring carrier to remove the process kit ring from the process kit enclosure system130to transport the process kit ring secured to the process kit ring carrier within the processing system100. In some embodiments, factory interface robot111may retrieve a process kit ring from a process kit enclosure system130and transport the process kit ring within the processing system100without use of a process kit ring carrier.

FIG.2Aillustrates a front view of a process kit enclosure system200, according to certain embodiments. The process kit enclosure system200may be used to securely hold process kit rings242and enable replacement of process kit rings242in a wafer processing system (e.g., processing system100ofFIG.1).

The process kit enclosure system200includes surfaces to at least partially enclose an interior volume202of the process kit enclosure system200. The surfaces of the process kit enclosure system200that enclose the interior volume202may include one or more of sidewalls210(e.g., right sidewall210A, left sidewall210B, etc.), a bottom surface212, a base plate214, a top cover216, a door frame250(seeFIG.2C), and a door252(seeFIG.2C). The door252of the process kit enclosure system200may be removable. For example, the door252may be attached to the process kit enclosure system200for transportation of the process kit enclosure system200. The door252may be removed from the process kit enclosure system200to expose a front interface (e.g., door frame250) of the process kit enclosure system200coupled to one or more of the surfaces of the process kit enclosure system200to interface the process kit enclosure system200with a load port of a wafer processing system (e.g., see processing system100ofFIG.1).

The process kit enclosure system200may meet one or more FOUP standards (e.g., size, weight, interface, handle clearance, etc.). For example, the process kit enclosure system200may interface with the same load port of a wafer processing system as a substrate FOUP. The process kit enclosure system200may have a weight of less than 35 pounds (lbs) for one-person lift. The process kit enclosure system200may meet one or more of the semiconductor equipment and materials international (SEMI) standards (e.g., use FOUP door per SEMI E15.1, docks on load ports per SEMI 47.1, sits on kinematic pins per SEMI E57, etc.).

One or more support structures230may be included in the interior volume202of the process kit enclosure system200. In some embodiments, two support structures230are disposed in the interior volume202to support content (e.g., content110ofFIG.1). In some embodiments, three support structures230are disposed in the interior volume202to support content (e.g., content110ofFIG.1) (e.g., seeFIGS.4C-E). In some embodiments, four support structures230are disposed in the interior volume202to support content (e.g., content110ofFIG.1) (e.g., seeFIGS.3C-E). Other numbers of support structures may also be used.

In some embodiments, the support structures230are comb structures. The support structures230may be made of a plastic (e.g., polyethylene) and a strengthening material may be disposed within the support structures230(e.g., a carbon fiber fill, one or more vertical rods of strengthening material through the support structures, etc.). Each support structure230may include one or more fins232(e.g., approximately horizontal fins) to support content. Each item of content may be supported by two or more fins (e.g., fin232A of support structure230A and a fin232B of support structure230B) that are approximately horizontal and approximately parallel to each other. The support structures230may support content so that an end effector on a robot arm of the wafer processing system can be inserted below the content, lift the content, and retract the content from the process kit enclosure system200.

The process kit enclosure system200may include two, three, or four support structures230in embodiments. Upper surfaces of the support structures230may be coupled to each other by a bridge bracket234(seeFIG.2F). Lower surfaces of the support structures230may be coupled to the base plate214. Upper surfaces of the fins232may include a feature (e.g., indentation, recess) to interface with surfaces proximate the perimeter (e.g., sidewalls, lower surface) of the process kit ring carrier240. For example, an upper surface of each fin232may have a recess and the process kit ring carrier240may be disposed in the recess. In some embodiments, the fins232support corners (e.g., where the perimeter transitions from curved to flat) of the process kit ring carrier240.

The fins232of the support structures230may be sized and spaced to provide a clearance between the upper surface of the process kit ring242and the lower surface of the fin232that is directly above the process kit ring242that allows for fin232recess height, robot arm droop and tolerance, and fin-to-fin tolerance.

The interior volume202of the process kit enclosure system200may include at least one process kit ring242(e.g., supported by corresponding fins232of support structures230) for automated transfer into the wafer processing system. A robot arm may remove the process kit ring242from the process kit enclosure system200for automated transfer to the process kit ring242to a process chamber of the wafer processing system. A robot arm may remove a used process kit ring from the process chamber for automated transfer into the process kit enclosure system200.

A process kit ring242in the process kit enclosure system200may be secured to an upper surface of a process kit ring carrier240. A robot arm may remove the process kit ring242from the process kit enclosure system200by inserting an end effector into the process kit enclosure system200below the process kit ring carrier240, lifting the process kit ring carrier240and the process kit ring242(e.g., by at least a portion of an upper surface of the end effector contacting at least a portion of the lower surface of the process kit ring carrier240), and extracting the process kit ring carrier240with the process kit ring242secured to the upper surface of the process kit ring carrier240. The space between the fins232of support structure230A and fins232of support structure230may allow the end effector to enter and lift content spanning from a fin232of support structure230A to a fin232of support structure230B without contacting the fins232.

As described herein, a process kit ring242on a process kit ring carrier240may refer to one or more process kit rings disposed on the process kit ring carrier240. For example, the process kit ring242may include two or more of an edge ring, processing ring, support ring, sliding ring, quartz ring, and/or the like that are disposed on the process kit ring carrier240.

In some embodiments, a process kit ring242may be disposed directly on the fins232and the robot arm may obtain a process kit ring carrier240(e.g., from within the wafer processing system) to lift the process kit ring242. In some embodiments, the robot arm may lift the process kit ring242without use of a process kit ring carrier240. One or more process kit rings242may be disposed on each process kit ring carrier240. For example, two or three process kit rings242may be nested within each other (e.g., a first process kit ring of a first diameter, a second process kit ring of a second diameter sized to fit within the first process kit ring, and a third process kit ring of a third diameter sized to fit within the second process kit ring) on the process kit ring carrier240.

Each support structure230may include multiple fins232that are sized and spaced to hold content in the interior volume202of the process kit enclosure system200. For example, one or more sets of substantially parallel fins232of support structures230may support an empty process kit ring carrier240(e.g., first set of substantially parallel fins232supports empty process kit ring carrier240A, second set of substantially parallel fins232supports empty process kit ring carrier240B). One or more sets of substantially parallel fins232of support structures230may support a process kit ring carrier240with a process kit ring242secured to the process kit ring carrier240. In some embodiments, the support structures230support one, two, three, four, five, six, seven, eight, or some other number of process kit ring carriers240with a corresponding process kit ring242secured to the process kit ring carrier240. In some embodiments, the fins232of support structures230support as many process kit ring carriers240with a corresponding process kit ring242secured to the process kit ring carrier240as there are processing chambers in the wafer processing system. For example, if the wafer processing system has six processing chambers, the process kit enclosure system200may include six process kit rings242(e.g., secured to a corresponding process kit ring carrier240). If the wafer processing system has eight processing chambers, the process kit enclosure system200may include eight process kit rings242(e.g., secured to a corresponding process kit ring carrier240).

A set of substantially parallel fins232of support structures230may support a placement validation wafer244(e.g., multi-function wafer). In some embodiments, the placement validation wafer244may be a similar size to wafers that are handled by the processing system. The placement validation wafer244may be located on a set of substantially parallel fins232to enable automated transfer of the placement validation wafer244into the wafer processing system to validate placement of process kit rings242in the wafer processing system. The fins used to support the placement validation wafer244may have a different spacing and/or size than the fins used to support the process kit rings and/or process kit ring carriers.

Each set of substantially parallel fins232may create a slot to support content. Each of one or more lower slots (e.g., the lowest slots) of the process kit enclosure system200may support an empty process kit ring carrier240. An upper slot (e.g., the top slot) of the process kit enclosure system200may support the placement validation wafer244. Each of one or more middle slots (e.g., above the empty process kit ring carriers240, below the placement validation wafer244) may support process kit ring carriers240that support a process kit ring242. One or more sets of substantially parallel fins232(e.g., slots for a process kit ring242on a process kit ring carrier240) may include a corresponding process kit ring orientation bracket. Each process kit ring orientation bracket may have one or more protrusions (e.g., pins) that engage with a flat portion of the interior surface of the process kit ring242to constrain movement (e.g., rotation, movement in x- and y-directions, etc.) of the process kit ring242. The one or more protrusions of the process kit ring orientation bracket and one or more features (e.g., pin contacts, recesses, etc.) of the process kit ring carrier240may constrain movement of the process kit ring242.

The robot arm may remove content (e.g., empty process kit ring carrier240, process kit ring carrier240securing a process kit ring242) from lower slots and place used content in the vacated lower slots to avoid contamination from used content (e.g., used process kit rings from the wafer processing system) falling on other content (e.g., new process kit rings242, placement validation wafer244). For example, one or more robot arms may remove an empty process kit ring carrier240A from the first slot, retrieve a used process kit ring using the empty process kit ring carrier240A, and replace the now full process kit ring carrier240A and supported used process kit ring at the first slot. The robot arm(s) may then remove a new process kit ring242C secured to a process kit ring carrier240C from a third slot above the first and second slots, place the process kit ring242C into a process chamber, and then replace the now empty process kit ring carrier240C back in the third slot. This process may be repeated with the process kit ring carrier240B and process kit ring242D and process kit ring carrier240D for a next process kit ring replacement, and so on.

An upper section of the process kit enclosure system200could include clean process kit rings242and a lower section could include dirty process kit rings242and empty process kit ring carriers240. In some embodiments, the process kit enclosure system200includes one or more physical dividers. The upper section and the lower section may be separated by a physical divider to avoid contamination. In some embodiments, dirty process kit rings242may be inserted into the process kit enclosure system200below the clean process kit rings242. In some embodiments, a first process kit enclosure system200can be used for dirty process kit rings242and empty process kit ring carriers240and a second process kit enclosure system200can be used for clean process kit rings242.

One or more handles222may be coupled to corresponding surfaces (e.g., exterior surfaces, sidewalls210) of the process kit enclosure system200for transporting the process kit enclosure system200. For example, handle222A may be coupled to sidewall210A and handle222B may be coupled to sidewall210B. The handles222may be configured for manual lifting and transporting of the process kit enclosure system200. In some embodiments, an overhead transfer (OHT) flange is coupled to an exterior surface (e.g., top cover216) of the process kit enclosure system200for transportation of the process kit enclosure system200.

The process kit enclosure system200may include a registration feature220(e.g., coupled or integral to the bottom surface212). The registration feature220may be used for robot calibration. The registration feature220may block a robot wafer mapper. The registration feature220may enable identification of the process kit enclosure system200as not being a wafer enclosure system (e.g., as not being a traditional FOUP carrying wafers). The registration feature220may enable identification of the process kit enclosure system200as a process kit enclosure system200. The registration feature may enable identification of the specific process kit enclosure system200or the type of content of the process kit enclosure system200. For example, the registration feature220may indicate that the process kit enclosure system200is supporting process kit rings242disposed on process kit ring carriers240. In some embodiments, the registration feature220is a simple tab, peg, protrusion, etc. A factory interface robot may be configured to perform wafer mapping of contents of FOUPs to determine the number of wafers in a FOUP, the placement of the wafers, and so on. However, the process kit rings and process kit ring carriers may be at unexpected locations that are different from locations at which wafers would generally be positioned. To perform wafer mapping, the robot arm may move an end effector or other wafer mapper head to a bottom of the process kit enclosure system200to begin a wafer mapping process. However, the end effector and/or mapper head will encounter the registration feature220, which may terminate the wafer mapping process. The presence of the registration feature220may provide a signal that indicates to controller109that a process kit enclosure system200is engaged to a load port rather than a traditional wafer-containing FOUP. In some embodiments, the process kit enclosure system200includes a registration feature220(e.g., FOUP type recognition feature via FI (front interface) robot mapping) and/or an auto-calibration feature (e.g., FI robot auto-calibration feature). The registration feature220may be located proximate the door frame250and the auto-calibration feature may protrude from proximate a center of a bottom surface of the interior (e.g., proximate the base plate214) of the process kit enclosure system200.

In some embodiments, one or more surfaces of the process kit enclosure system200have a transparent window218that enables a view of the process kit ring carriers240and the process kit rings242. For example, a rear surface of the process kit enclosure system200may have a window218(e.g., seeFIGS.2A and2E) and/or a top cover216of the process kit enclosure system200may have a window218(e.g., seeFIG.2B). The window may enable operators to visually inspect the contents of the process kit enclosure system to determine that process kit rings and/or process kit ring carriers are correctly stored therein, for example.

Content that enters the process kit enclosure system200from the wafer processing system may have corrosive substances (e.g., Hydrogen Bromide (HBr)) thereon. The process kit enclosure system200may be sealed to the load port of the wafer processing system to avoid escape of corrosive substances from the wafer processing system and process kit enclosure system200. The process kit enclosure system200may be sealed to the load port of the wafer processing system for cleaning of the process kit enclosure system (e.g., decontamination of internal surfaces and features). Any electronics (e.g., battery, communications, sensors, microcontroller unit (MCU), etc.) associated with the process kit enclosure system (e.g., disposed in, coupled to) may be sealed

The materials of the process kit enclosure system200may be compatible with corrosive substances (e.g., HBr). For example, the materials of the process kit enclosure system200may include one or more of polyethylene, acrylonitrile ethylene propylene diene monomer (AEPDM), ethylene propylene diene monomer (EPDM), perfluoroelastomer (FFKM) (e.g., Chemraz®), fluoroelastomer material (FKM) (e.g., Viton®), and/or polytetrafluoroethylene (PTFE) (e.g., Teflon®). The process kit enclosure system200may have purge ports (e.g., in the base plate214, etc.). The purge ports may be used for a nitrogen purge (e.g., N2purge). For example, after the used process kit rings242are transferred to the process kit enclosure system200, the purge ports may be used to clean contaminants from the process kit enclosure system200(e.g., transfer nitrogen gas into the process kit enclosure system200to evacuate HBr, etc. from the process kit enclosure system200). One or more first purge ports may be used to push gas into the process kit enclosure system200and one or more second purge ports may be used to remove gas from the process kit enclosure system200. In some embodiments, the process kit enclosure system200does not have any purge ports.

The base plate214of the process kit enclosure system200may include features (e.g., locating pins, mounting holes) to enable lower surfaces of the support structures230to engage with the base plate214(e.g., the bottom surface212may form corresponding holes for the engaging of the support structures230with the base plate214).

The base plate214may include features (e.g., bearing surface) to enable lower surfaces of retention devices260(e.g., seeFIG.2F) to engage (e.g., rotatably couple) with the base plate214.

The base plate214may include features (e.g., mounting holes) to enable the bottom surface212of the process kit enclosure system200to engage with the base plate214.

The base plate214may include features (e.g., locating pins, mounting holes) to enable the door frame to engage with the base plate214(e.g., a sidewall of the door frame to engage with a sidewall of the base plate214). The base plate214may include features (e.g., an auto-teaching mounting hole, FOUP docking track latch clamping feature, load port kinematic pin features, load port datum pin clearance, FOUP presence switch features, etc.) for docking the process kit enclosure system200on the wafer processing system (e.g., mounting the base plate214on a surface proximate the load port).

The front interface of the process kit enclosure system200may include a door frame250(seeFIG.2C,FIG.2Amay not display the door frame250). The door frame250may include features (e.g., recesses) to enable the door frame250to engage with the base plate214. The door frame250may include features (e.g., threaded inserts, such as screws, inserted into channels through the door frame250to engage with sidewalls210) to enable the door frame250to engage with sidewalls210of the process kit enclosure system200. The door frame250may have features (e.g., sealed load port side clamping features, recesses to receive clamp from load port) to enable the process kit enclosure system200to seal to the load port. The door frame250and/or door252may include features to couple to each other.

The process kit enclosure system200may include surfaces to partially enclose the interior volume202. A portion of the surfaces may form an enclosure component that is a rectangular prism (e.g., cube) that has cutouts for transparent windows218and features. The enclosure component may include the bottom surface212, the sidewalls210A-B, a front lip, a top lip, and a rear lip. The front lip of the enclosure component may interface with the door frame. The top lip of the enclosure component may couple with the top cover216. The top lip of the enclosure component may have a cutout for insertion of the support structures230into the interior volume202. The rear lip of the enclosure component may couple with a window218. The bottom surface212may include features (e.g., retention device lower pivot pins) for coupling to the retention devices260. The bottom surface212may include features (e.g., cutouts) to allow the support structures230to mount to the base plate214. The bottom surface212may be coupled to a registration feature220(e.g., process kit enclosure system200recognition feature). In some embodiments, the registration feature220and the bottom surface212are integral to each other.

FIG.2Billustrates a top view of a process kit enclosure system200, according to certain embodiments.

The top cover216of the process kit enclosure system200may include an upper surface and one or more flanges. The top cover216may include a docking offset flange for docking to the load port. The upper surface of the top cover216may have a window cutout for a transparent window218. The upper surface of the top cover216may be coupled to the enclosure component by one or more fasteners (e.g., captive thumbscrews). The retention devices260may be taller than the top cover216and may be captured by the features (e.g., dimples) of the upper surface of the top cover216. The base (e.g., lower portion) of each retention device260may be pinned to allow the retention devices260to rotate about z-axis (e.g., and to be removed for docking to the load port). Each retention device260may have features (e.g., approximately horizontal fins) that prevent content from coming out of the recess in the fins232of the support structures230. There may be two retention devices260that have an angular pitch (e.g., not at 180 degrees). The features (e.g., dimples) in the upper surface of the top cover216may be sized to receive the retention features in the secured position (e.g., first rotated state) or unsecured position (e.g., second rotated state, removed, etc.).

In some embodiments, the top cover216has a docking position (e.g., docking flange on the same side as the door frame) and a transport position (e.g., docking flange on the same side as the rear window218). The fasteners may be used to remove the top cover216in a first position and to attach the top cover216in a second position. The features (e.g., dimples) in the top cover216in the transport position may only receive the retention devices260in the secured position. The features (e.g., dimples) in the top cover216in the docking position may only receive the retention devices260in the unsecured position. In some embodiments, the secured position is rotating the retention devices260to secure the content on the fins232of the support structures230. In some embodiments, the unsecured position is rotating the retention devices260to not secure the content on the fins232of the support structures230. In some embodiments, the unsecured position is removing the retention devices260from the interior volume202of the process kit enclosure system200(e.g., removing the retention devices260prior to attaching the top cover216in the docking position).

In some embodiments, the top cover216includes a transparent window218to provide a view of the content on the support structures. In some embodiments, the top cover216does not include a transparent window218.

FIG.2Cillustrates a side view of a process kit enclosure system200, according to certain embodiments. A door frame250may be coupled to the sidewalls210and the base plate214. A door252may be coupled to the door frame250for transportation of the process kit enclosure system200. The door252may be removed from the process kit enclosure system200to load the process kit enclosure system200with content. The door252may be removed from the process kit enclosure system200to couple the process kit enclosure system200with the load port.

FIG.2Dillustrates a bottom view of a process kit enclosure system200, according to certain embodiments. A base plate214may be disposed at the bottom of the process kit enclosure system200. The base plate214may interface (e.g., have features that interface) with one or more features (e.g., kinematic pins, clamp, etc.) of a wafer processing system proximate the loading port. The base plate214may be coupled to one or more load port presence sensors, load port couplings interface, recesses, etc.

FIG.2Eillustrates a rear view of a process kit enclosure system200, according to certain embodiments. In some embodiments, a transparent window218is coupled to the rear lip of the enclosure component of the process kit enclosure system200to provide a view of the content on the support structures230. In some embodiments, a rear surface of the process kit enclosure system200does not include a transparent window218(e.g., instead of a rear lip, the enclosure component may include a rear sidewall210C).

FIG.2Fillustrates the support structures230and retention devices260of a process kit enclosure system200, according to certain embodiments.

Content supported on the fins232of the support structures230may be constrained during transportation. For example, one or more retention devices260may secure each of the process kit rings242to a corresponding one of the process kit ring carriers240and may further secure each of the process kit ring carriers240within the process kit enclosure system200during transportation of the process kit enclosure system200. A lockout feature (e.g., of the retention devices) may block engaging of the process kit enclosure system200with the load port of the wafer processing system responsive to the one or more retention devices260being in a secured position. The lockout feature may allow engaging of the process kit enclosure system200with the load port responsive to the retention devices260being in an unsecured position (e.g., removed or not engaging with an upper surface of the content). In some embodiments, coupling of the door252to the process kit enclosure system200may place the retention devices260in a secured position and removal of the door252from the process kit enclosure system200may place the retention devices260in an unsecured position. In some embodiments, to interface (e.g., engage, dock, etc.) the front interface of the process kit enclosure system200with the load port, the door252is removed, the top cover216is removed, the retention devices260are placed in the unsecured position (e.g., removed, rotated), and the top cover216attached in a docking position (e.g., rotated from the original transport position). The process kit enclosure system200may not dock without the top cover216in the docking position and the top cover216may not attach in the docking position without the retention devices260being in the unsecured position. To transport the process kit enclosure system200, the top cover216may be removed, the retention devices260may be placed in a secured position (e.g., inserted in the interior volume202and/or rotated), the top cover216may be attached in the transport position (e.g., the top cover216may not be able to attach in the transport position if the retention devices260were not in the secured position), and the door252may be coupled to the process kit enclosure system200(e.g., the door252may not be able to attach when the top cover216is in the transport position). The retention devices260may be rotatable to the secured position to secure the process kit ring carriers240. The retention devices260may also be rotatable to the unsecured position to cause each of the plurality of process kit ring carriers240to be unsecured.

The process kit ring carrier240and the process kit ring242secured to the process kit ring carrier240may be retained (e.g., by one or more retention devices260) to minimize movement of the process kit ring carrier240and process kit ring242. Process kit ring carriers240and/or process kit rings242may be retained by one or more of: friction; vacuum pads and a pilot check valve; passive edge grip; passive self-aligning; semi-active edge grip (e.g., human or machine rotated comb or lever, variable height adjustable comb to support variations of process kit ring sizes (e.g., predetermined or variable)); closing of the door252actuating retention devices260; lever couple clamps carrier when process kit ring carrier240is seated due to weight of the process kit ring carrier240and process kit ring242; one or more pneumatically powered clamps; and/or lever activated by sensor and retention devices260powered by an actuator.

In some embodiments, the process kit enclosure system200(e.g., support structures230and/or retention device) may capture six degrees of freedom (e.g., x-translation, y-translation, z-translation, x-rotation, y-rotation, and z-rotation) of the process kit ring carriers240and/or the process kit rings242. The process kit ring242may be constrained in x-translation, y-translation, and z-rotation by features (e.g., buttons, extrusions) of the process kit ring carrier240. The process kit ring242may be constrained in z-translation, x-rotation, and y-rotation by gravity. Responsive to the process kit ring242being effectively fully constrained on the upper surface of the process kit ring carrier240(e.g., by features of the process kit ring carrier240and gravity), the process kit enclosure system200(e.g., support structures230and/or retention devices260) may be used to support and constrain the process kit ring carrier240.

The process kit ring carrier240may have a perimeter that includes two curved edges that are opposite each other and two flat edges (e.g., parallel edges, straight edges) that are substantially parallel to each other. The support structures230may support the process kit ring carriers240at the flat edges.

In some embodiments, the retention devices260may capture six degrees of freedom of the process kit ring carriers240and the process kit rings242. In some embodiments, the support structures230and the retention devices260may capture six degrees of freedom of the process kit ring carriers240and the process kit rings242.

In some embodiments, the process kit enclosure system200includes a microcontroller and battery to positively secure the content on the support structures230. For example, a microcontroller could place (e.g., rotate) the retention device260into a secured position (e.g., responsive to input that the process kit enclosure system200is to be transported) and into an unsecured position (e.g., responsive to input that the process kit enclosure system200is to be docked).

In some embodiments, the fins262of the retention device260may secure content of different heights. For example, the fins262may secure an empty process kit ring carrier240on a first set of fins232of the support structure (e.g., during transporting of the process kit enclosure system200to the loading port) and the fins262may secure a used process kit ring on a process kit ring carrier240on the first set of fins232of the support structure (e.g., during transporting of the process kit enclosure system200from the loading port after replacement of one or more process kit rings). For example, the fins262may be mass hooks that adjust for different heights of content on the fins232of the support structures230.

FIG.3Aillustrates a cross sectional view of content (e.g., a process kit ring carrier340(e.g., process kit ring carrier240ofFIG.2A) or placement validation wafer344(e.g., placement validation wafer244ofFIG.2A)) on a fin332(e.g., fin232ofFIG.2A) of a support structure330(e.g., support structure230ofFIG.2A) of a process kit enclosure system300(e.g., process kit enclosure system200ofFIG.2A), according to certain embodiments. The fin332may form a recess and the content may be disposed in the recess. In some embodiments, an upper surface of the content includes an extrusion to couple with a process kit ring342(e.g., process kit ring242).

FIG.3Billustrates a cross sectional view of a process kit ring342disposed on a process kit ring carrier340on a fin332of a support structure330of a process kit enclosure system300, according to certain embodiments. The process kit ring342may be constrained in x-translation, y-translation, and z-rotation by the extrusion of the process kit ring carrier340. The process kit ring342may be constrained in z-translation, x-rotation, and y-rotation by gravity.

FIG.3Cillustrates a top view of a process kit ring carrier340on fins332of support structures330of a process kit enclosure system300, according to certain embodiments. The process kit ring carrier340may be placed on the fins332manually or by a robotic arm. In some embodiments, the process kit enclosure system300may include four support structures330that each includes corresponding fins332.

FIG.3Dillustrates a top view of retention devices360(e.g., retention devices260ofFIG.2F) and a process kit ring342disposed on a process kit ring carrier340on fin332of support structures330of a process kit enclosure system300, according to certain embodiments. The upper surface of the process kit ring carrier340may have one or more extrusions (e.g., one extrusion per fin332). The one or more extrusions may capture degrees of freedom (e.g., constrain movement) of the process kit ring342.

FIG.3Eillustrates a top view of retention devices360securing a process kit ring342disposed on a process kit ring carrier340on a fin332of a support structure330of a process kit enclosure system300, according to certain embodiments. The retention devices360may be rotated so that lower surfaces of the retention device360(e.g., lower surfaces of fins362of the retention device360) are above the content on the fins332. In some embodiments, the retention devices360are in contact with an upper surface of the content on the fins332. For example, the fins362of the retention devices360may be in contact with an upper surface of the process kit rings342. In some embodiments, the retention devices360are disposed above the content so that the content cannot fall from the fins332. For example, the distance between a lower surface of the fins362of the retention devices360and the upper surface of the process kit rings342may be less than the height of the extrusions on the upper surface of the process kit ring carrier340.

FIGS.4A-Iillustrate content disposed on one or more fins432of a process kit enclosure system400, according to certain embodiments. In some embodiments, the content (e.g., process kit ring carrier440, placement validation wafer444) has a planar bottom surface on a first plane and has one or more features (e.g., extrusions, pads) that extend from the first plane. For example, the process kit ring carrier440may have one or more pads that wrap from a side surface of the process kit ring carrier440to a bottom surface of the process kit ring carrier440. Each fin432may have a recess (e.g., slot) to receive the feature (e.g., pad) of the process kit ring carrier440. In some embodiments, only the features of the process kit ring carrier440engage with the fin432(e.g., the planar bottom surface of the process kit ring carrier440does not engage with the fins432). In some embodiments, the recesses of the fins432(that receive the pads of the process kit ring carrier440) constrain movement of the process kit ring carrier440in the x-direction and the y-direction.

FIG.4Aillustrates a cross sectional view of content (e.g., a process kit ring carrier440(e.g., process kit ring carrier240ofFIG.2A) or placement validation wafer444(e.g., placement validation wafer244ofFIG.2A)) on a fin432(e.g., fin232ofFIG.2A) of a support structure430(e.g., support structure230ofFIG.2A) of a process kit enclosure system400(e.g., process kit enclosure system200ofFIG.2A), according to certain embodiments. The fin432may form a first recess and the content may be disposed in the first recess. The fin432may form a second recess to couple with a process kit ring442(e.g., process kit ring242).

FIG.4Billustrates a cross sectional view of a process kit ring442disposed on a process kit ring carrier440on a fin432of a support structure430of a process kit enclosure system400, according to certain embodiments. The process kit ring442may be constrained in x-translation, y-translation, and z-rotation by the second recess of the fin432of the support structure430. The process kit ring442may be constrained in z-translation, x-rotation, and y-rotation by gravity. The process kit ring carrier440may have a slot452. The slot may correspond to a registration feature of the process kit ring442(e.g., flat interior sidewall surface or other registration feature of the process kit ring442). In some embodiments a fin432may be sized and shaped (e.g., have a corresponding feature) for constraining movement of the process kit ring442. For example, the fin432may have a second recess sized to receive the process kit ring442. In some embodiments, a process kit ring orientation bracket may have one or more protrusions (e.g., pins) that engage with the registration feature of the process kit ring442(e.g., flat interior sidewall surface) for constraining movement of the process kit ring442.

FIG.4Cillustrates a top view of a process kit ring carrier440on fins432of support structures430of a process kit enclosure system400, according to certain embodiments. The process kit ring carrier440may be placed on the fins432manually or by a robotic arm. In some embodiments, the process kit enclosure system400may include three support structures430that each includes corresponding fins432. In some embodiments, fins432of each of the support structures430form the first recess and fins432of one of the support structures430forms the second recess. The process kit ring carrier440may be disposed on one or more fins432(e.g., two fins, three fins, four fins, etc.).

FIG.4Dillustrates a top view of retention devices460(e.g., retention devices260ofFIG.2F) and a process kit ring442disposed on a process kit ring carrier440on fin432of support structures430of a process kit enclosure system400, according to certain embodiments. A portion of the process kit ring442may be disposed within the second recess of a fin432of a support structure430. The second recess formed by the fin432may capture degrees of freedom (e.g., constrain movement) of the process kit ring442.

FIG.4Eillustrates a top view of retention devices460securing a process kit ring442disposed on a process kit ring carrier440on a fin432of a support structure430of a process kit enclosure system400, according to certain embodiments. In some embodiments, the retention devices460may be rotated so that lower surfaces of the retention device460(e.g., lower surfaces of fins462of the retention device460) are above the content on the fins432. In some embodiments, the retention devices460are in contact with an upper surface of the content on the fins432. For example, the fins462of the retention devices460may be in contact with an upper surface of the process kit rings442. In some embodiments, the retention devices460are disposed above the content so that the content cannot fall from the fins432. For example, the distance between a lower surface of the fins462of the retention devices460and the upper surface of the process kit rings442may be less than the height to be overcome to remove the process kit ring442from the second recess. In some embodiments, retention devices460may be placed in an unsecured position (e.g., rotated, rotated and removed, etc.) to transfer content (e.g., a process kit ring carrier440and/or a process kit ring442on a process kit ring carrier440) into a processing system. In some embodiments, a retention device460may pivot to secure the process kit ring carrier440and/or process kit ring442responsive to a portion of the process kit ring carrier440engaging with the retention device.

FIGS.4F-Iillustrate cross sectional views of content (e.g., a process kit ring carrier440) and a fin432of a process kit enclosure system400, according to certain embodiments. In some embodiments, the retention device460may be a pivoting clamp. When content (e.g., a process kit carrier440) is not on the fin432, the center of gravity of the retention device460may cause a clamp portion of the retention device460to be oriented to receive a content (e.g., as shown inFIGS.4F and4H, the clamp portion of the retention device460may be oriented upward). Upon lowering the content (e.g., process kit ring carrier440with or without a process kit ring442on the process kit ring carrier440) onto the fin432, the process kit ring carrier440may engage with the retention device460(e.g., with the clamp portion of the retention device460) to cause the retention device460to pivot to a secured position (e.g., a first portion of the clamp portion of the retention device460above the process kit ring carrier440and a second portion of the clamp portion of the retention device460below the process kit ring carrier440. In some embodiments, the clamp portion of the retention device460may be sized to receive one or more of a placement validation wafer444, the process kit ring carrier440, or the process kit ring442(e.g., the process kit ring442disposed on the process kit ring carrier440). The process kit ring carrier440may have a one or more features (e.g., pad, foot, etc.), where a corresponding feature engages with each fin432(e.g., a recess of each fin432). The one or more features may be the only portion of the process kit ring carrier440that engage with the fins432.

FIG.5illustrates a method500for process kit ring replacement in processing chambers, according to certain embodiments. Although shown in a particular sequence or order, unless otherwise specified, the order of the processes can be modified. Thus, the illustrated embodiments should be understood only as examples, and the illustrated processes can be performed in a different order, and some processes can be performed in parallel. Additionally, one or more processes can be omitted in various embodiments. Thus, not all processes are required in every embodiment.

Content may be disposed in an interior volume of a process kit enclosure system. The content may be disposed on fins of support structures (e.g., comb structures) disposed in the interior volume of the process kit enclosure system. The content may include one or more of process kit ring carriers (e.g., empty or with a process kit ring disposed on the process kit ring carrier), process kit rings (e.g., disposed on the fins of the support structures, disposed on process kit ring carriers), or a placement validation wafer. The content may be manually loaded in the process kit enclosure system or the loading of the content into the process kit enclosure system may be automated (e.g., using robot arms).

At block502, the content may be secured within the process kit enclosure system by placing one or more retention devices of the process kit enclosure system in a secured position. Retention devices may be rotated to secure the content to (e.g., prevent the content from falling from, prevent the content from going over features of) the fins of the support structures. For example, a top cover may be removed from the process kit enclosure system, the retention devices may be inserted into the interior volume of the process kit enclosure system so that the base of the retention devices couples with a pin at a bottom surface (and/or base plate) of the interior surface, the retention devices may be rotated so that the fins of the retention devices are above content on the fins of the support structures, and the top cover may be reattached to the process kit enclosure system. The top cover may not reattach unless the retention devices are rotated to be above the content on the support structures (e.g., un-rotated retention devices may block the attachment of the top cover, retention devices in a secured position may line up with dimples in the top cover whereas retention devices in an unsecured position may not line up with dimples).

At block504, the process kit enclosure system may be transported to a wafer processing system. The process kit enclosure system may be manually transported by using one or more handles. The transportation of the process kit enclosure system may be automated using a handle (e.g., sidewall handles, OHT, etc.). A cart with robotic forks may be used for pulling and/or placing the process kit enclosure system from/to the load port.

At block506, the content may be unsecured within the process kit enclosure system by placing the one or more retention devices of the process kit enclosure system in an unsecured position. In one embodiment, the top cover is removed, the retention devices are rotated to an unsecured position (e.g., to not be above the content on the support structures), are removed from the interior volume, and the top cover is re-attached.

At block508, the front interface of the process kit enclosure system may be interfaced with a load port of the wafer processing system. For example, clamps may secure the door frame of the process kit enclosure system to the load port. The front interface of the process kit enclosure system and the load port may be sealed (e.g., an air seal).

At block510, a robot arm may remove a first process kit ring carrier from the process kit enclosure system. The first process kit ring carrier may be empty. The robot arm may remove the first process kit ring carrier from a lower slot (e.g., bottom slot or slot above used process kit rings). The first process kit ring carrier may be the lowest empty process kit ring carrier in the process kit enclosure system. The robot arm may transfer the first process kit ring carrier into the wafer processing system.

At block512, a used process kit ring from a processing chamber of the wafer processing system may be placed on the first process kit ring carrier. Lift pins (e.g., process kit ring lift pins) in the processing chamber may lift the used process kit ring, a robot arm may place the first process kit ring carrier below the used process kit ring, and the lift pins may lower to place the used process kit ring on the first process kit ring carrier.

At block514, the robot arm may insert the used process kit ring secured to the first process kit ring carrier into the process kit enclosure system. The robot arm may place the used process kit ring secured to the first process kit ring carrier into the slot (e.g., lower slot) from which the first process kit ring carrier was removed.

At block516, the robot arm may remove a new process kit ring secured to a second process kit ring carrier from the process kit enclosure system. The new process kit ring secured to the second process kit ring carrier may be in an upper slot of the process kit enclosure system that is above the lower slot corresponding to the first process kit ring carrier. The new process kit ring secured to the second process kit ring carrier may be in the lowest slot out of all of the new process kit rings in the process kit enclosure system (e.g., there may not be any new process kit rings below the new process kit ring secured to the second process kit ring carrier).

At block518, the new process kit ring may be placed into the processing chamber. A robot arm may transfer the new process kit ring secured to the second process kit ring carrier into the processing chamber, the lift pins (e.g., process kit ring lift pins) in the processing chamber may lift the new process kit ring off of the second process kit ring carrier, the robot arm may retract the process kit ring carrier from the processing chamber, and the lift pins may lower the new process kit ring into position within the processing chamber.

At block520, the robot arm may insert the second process kit ring carrier (now empty) into the process kit enclosure system. The robot arm may insert the second process kit ring carrier into the same slot from which the new process kit ring secured to the second process kit ring carrier was removed.

At block522, a placement validation wafer may be transferred from the process kit enclosure system to validate placement of the new process ring in the processing chamber of the wafer processing system. The placement validation wafer may be disposed in a slot above the used process kit rings. The placement validation wafer may be dispose in an uppermost slot of the process kit enclosure system. The robot arm may remove the placement validation wafer for validation of placement of the new process ring.

Prior to causing transportation of the process kit enclosure system away from the wafer processing system, the content is to be secured within the process kit enclosure system by placing the one or more retention devices of the process kit enclosure system in a secured position. In one embodiment, the top cover is removed, the retention devices are placed into the interior volume, the retention devices are rotated to a secured position (e.g., to be above the content on the support structures), and the top cover is re-attached. The front interface of the process kit enclosure system may be unsecured from a load port of the wafer processing system (e.g., clamps securing the door frame of the process kit enclosure system to the load port may be unsecured). The door of the process kit enclosure system may be attached to the door frame after unsecuring the process kit enclosure system from the load port.