METHOD AND APPARATUS FOR SECURING SEMICONDUCTOR DEVICE CARRYING BOAT IN MULTI-BOAT TRAY

A tray of an automated handling system for transporting semiconductor devices includes: a receiving region that is configured to receive a boat, the boat carrying one or more semiconductor devices thereon; and a clamping mechanism that selectively clamps the boat, residing in the receiving region, to the tray. Suitably, the clamping mechanism is automatically disengaged when the tray is positioned in a designated location and automatically engaged when the tray is not positioned in the designated location, such that, when engaged, the clamping mechanism holds the boat, residing in the boat receiving region, securely within the tray, and when disengaged, the clamping mechanism releases the boat residing in the boat receiving region.

BACKGROUND

The following relates to the semiconductor arts, and in particular, to a method and apparatus for transporting and/or handling semiconductor devices during the manufacturing process.

DETAILED DESCRIPTION

In general, semiconductor devices, for example, such as Metal-Oxide-Semiconductor Field-Effect Transistor (MOS-FET) devices, Fin Field-Effect Transistor (FinFET) devices, Gate All Around Field-Effect Transistor (GAA-FET) devices, Integrated Circuits (ICs), etc. are manufactured and/or fabricated from and/or on semiconductor wafers and/or suitable substrates in a semiconductor fabrication plant, commonly referred to as a FAB or foundry. There are commonly many processing steps applied to the semiconductor wafer or substrate to produce a desired semiconductor device and/or numerous semiconductor devices on a wafer or suitable substrate. For example, semiconductor fabrication can be a multiple-step sequence of photolithographic, mechanical and/or chemical processing steps (for example, such as surface passivation, thermal oxidation, planar diffusion, junction isolation, etc.) during which electronic circuits and/or semiconductor devices are gradually created on the semiconductor wafer. Accordingly, a FAB clean room or other like space where semiconductor device fabrication takes place typically contains many individual pieces of machinery and/or tools for semiconductor device production, for example, without limitation, such as steppers and/or scanners for photolithography, in addition to tools for material deposition, etching, cleaning, doping, testing, inspecting, dicing, wafer annealing, etc. and load ports or the like for temporary staging and/or storage of semiconductor wafers and/or devices. During the fabrication process which may include, without limitation: front-end-of-line (FEOL) process steps, a middle-end-of-line (MEOL) process steps, a back-end-of-line (BEOL) process steps, die preparation process steps and/or a semiconductor and/or IC packaging process steps, semiconductor wafers and/or devices are commonly transported from tool to tool and/or otherwise transferred to and/or from processing and/or holding chambers of various tools and/or equipment using an automated handling system (AHS). For example, such automated handling systems may include, without limitation, one or more of: an Equipment Front End Module (EFEM), robotic arms, linear conveyors, rotating conveyors or turn tables, grippers, overhead transport (OHT), and the like.

For efficiency and/or to increase throughput in the semiconductor manufacturing process, one or more semiconductor devices may be arranged and/or contained in an individual carrier, known as a boat, so that the semiconductor devices within the boat may be simultaneously transported, handled and/or processed at various stages of the semiconductor manufacturing process. A boat may, for example, be made of quartz or another material that can withstand processing conditions such as high thermal temperature, exposure to various gases, and/or so forth. Moreover, at various stages within the manufacturing process, efficiency and/or throughput in the semiconductor manufacturing process may also be enhanced by similarly situating one or more boats within a larger individual tray provisioned to carry one or more boats. For example, the tray may be designed to be loaded into an OHT vehicle for transport between semiconductor processing or characterization tools.

In practice, at particular points in the semiconductor manufacturing process, a boat may be selectively emptied (i.e., semiconductor devices removed therefrom), filled (i.e., semiconductor devices loaded therein) and/or re-used repeatedly in subsequent processing cycles and/or at various points within the same processing cycle. Likewise, at particular points in the semiconductor manufacturing process, a tray may be selectively emptied (i.e., boats removed therefrom), filled (i.e., boats loaded therein) and/or re-used repeatedly in subsequent processing cycles and/or at various points within the same processing cycle.

Suitably, in accordance with some embodiments disclosed herein, an individual tray is formed with one or more receiving wells or regions in which one or more boats may be selectively placed. Advantageously, each receiving well or region is sized appropriately for the individual boat being received therein. In some suitable embodiments, one or more inner dimensions of a tray's receiving well or region may be slightly larger than the corresponding outer dimensions of a boat received therein. One advantage of this slight difference or tolerance is that it may permit and/or facilitate the boat to be readily placed and/or fit within the receiving region of the tray, for example, with less than absolute precision, and in turn, demands on the precision of an automated handling device placing and/or fitting the boat in a receiving well or region within the tray may be alleviated. However, this slight difference or tolerance between the one or more inner dimensions of the receiving well or region and the one or more outer dimensions of the boat may potentially allow a boat to move, vibrate, shake and/or rattle about within the receiving well or region of the tray, for example, when the tray is being transported and/or otherwise handled, and particularly, when a tray is rotated or moved at high speed.

Accordingly, in some suitable embodiments disclosed herein, a tray is provisioned with one or more clamping mechanisms that selectively secure one or more boats carried in the tray. One advantage of such a clamping mechanism is that the boats are not free to move, vibrate, shake or rattle about within the tray as the tray is being moved, transported or otherwise handled, hence, the clamping mechanism aids in avoiding and/or mitigating the potential for damage to the semiconductor devices carried in the boats, which damage might otherwise result from such movement, vibration, shaking or rattling of the boat within the tray. That is to say, advantageously, the clamping mechanisms may be selectively employed to stabilize the boats within the tray when the tray is being transported and/or otherwise handled, while still permitting suitable tolerances to exist between the inner dimensions of the receiving well or region and the outer dimensions of the boat, which tolerances facilitate the boat being readily placed and/or fit within the receiving well or region.

A further advantage of the clamping mechanisms disclosed herein is that the clamping mechanism may move and/or secure the boat to a relatively precise location with respect to the tray, and hence, the location of semiconductor devices within the boat may be more precisely known and/or sufficiently controlled in repetitive fashion, which can aid in subsequent processing of the semiconductor devices. That is to say, the clamping mechanisms may move and/or secure a boat to a particular location within the receiving well or region that the boat was placed and do so repeatedly and reliably with each subsequent use of the tray.

In some suitable embodiments, the clamping mechanism is a primarily mechanically driven, non-powered (i.e., not powered or driven electrically, magnetically, pneumatically or hydraulically) mechanism that selectively engages and/or disengages automatically as the tray is otherwise moved, transported and/or handled. An advantage of such a mechanically driven clamping mechanism is that it remains relatively simple and/or uncomplicated to implement and it may be readily provided on a tray which remains highly portable and may withstand the different environments (for example, such as a relatively high temperature environment) to which the tray may be exposed during various semiconductor manufacturing process steps. For example, the tray in some embodiments does not include a power source for driving the clamping mechanism.

In accordance with some suitable embodiments disclosed herein,FIG.1shows an automated handling system (AHS)100for transporting and/or otherwise handling semiconductor devices during a semiconductor manufacturing process. In some suitable embodiments, the AHS100may include, without limitation: (i) a magazine load port (MLP)102or the like; (ii) one or more conveyor lanes104or the like; (iii) a linear table or stage106or the like; (iv) automated grippers108or the like; (v) a turn table or stage110or the like; (vi) an EFEM, for example, including a dual-arm robot112, or the like; and (vii) a buffer table or stage114or the like.FIG.1also show a process tool200that applies one or more semiconductor manufacturing process steps (including, for example, testing) to semiconductor devices loaded therein, for example, including without limitation: a front-end-of-line (FEOL) process step, a middle-end-of-line (MEOL) process step, a back-end-of-line (BEOL) process step, a die preparation process step and/or a semiconductor and/or IC packaging process step. It will be appreciated that a given embodiment may include a subset of these handling equipment, and/or may include other types of handling equipment besides the above nonlimiting illustrative examples.

In some suitable embodiments, the MLP102may temporarily store and/or house one or more semiconductor device carrying boats300. In practice, each boat300may carry one or more semiconductor devices302therein. For example, each semiconductor device302may be, without limitation, a MOS-FET device, a FinFET device, a GAA-FET device, IC, etc. In one typical example, each semiconductor device302may be an IC fabricated (or in the process of fabrication) on a silicon wafer, silicon-on-insulator (SOI) wafer, or so forth, and the circuitry of the IC of each device302may include various electronic components such as MOS-FETs, FinFETs, GAA-FETs, capacitors, and/or so forth. Depending on the stage of the processing, each semiconductor device302may be a full wafer (e.g. silicon, SOI, or other semiconductor wafer), or each device302may be a chip diced from such a wafer. For illustrative purposes, as shown, each boat300is carrying 8 semiconductor devices302therein. In practice, each boat300may carry more or less than 8 semiconductor devices302. In some nonlimiting illustrative embodiments, each boat300is configured to carry between 1 semiconductor device302and 32 semiconductor devices302.

In some suitable embodiments, the boats300are in turn selectively unloaded from the MLP100, for example, being transported along and/or by one or more of the conveyor lanes104. The automated grippers108are operably movable along the linear table106and may selectively retrieve the boats300, for example, from an end of the conveyor lanes104and selectively place one or more of the retrieved boats300in a tray400, for example, positioned on and/or located atop the turn table110. In some suitable embodiments, the robot112may selectively retrieve the tray400from the turn table110and load the retrieved tray400into the process tool200, for example, placing and/or putting the tray400into a chamber of the process tool200. Alternatively, the robot112may selectively place and/or put a retrieved tray400on or atop the buffer table114.

For illustrative purposes, inFIG.1, the robot112is shown holding a tray400and a tray400is shown residing in the process tool200. However, in practice, at various times, the tray400may in fact reside and/or rest upon the turn table110and/or the buffer table114.

FIG.2shows a tray400with boats300residing therein. Suitably, each tray400includes one or more boat receiving wells or regions402into which a boat300may be selectively placed, for example, by the automated grippers108. In practice, each receiving well or region402may be sized slightly larger than an individual boat300being received therein. That is to say, for example, in some suitable embodiments, one or more inner dimensions of a tray's receiving well or region402may be slightly larger than the corresponding outer dimensions of a boat300received therein. Accordingly, this slight difference or tolerance between the respective sizes and/or dimensions may permit and/or facilitate the boat300to be readily placed and/or fit within the receiving well or region402of the tray400.

For illustrative purposes, inFIG.2, the tray400is shown having 2 boat receiving wells or regions402. In practice, each tray400may have more or less than 2 boat receiving wells or regions402.

In some suitable embodiments, the tray400is provisioned with one or more selectively engageable clamping mechanisms410. For illustrative purposes, inFIG.2, the tray400is shown having 6 clamping mechanisms410, with three clamping mechanisms410engaging each boat300. In practice, each tray400may have more or less than 6 clamping mechanisms410. Suitably, the tray400may have one or more clamping mechanisms410associated with each boat receiving well and/or region402of the tray400. In suitable embodiments, the clamping mechanisms410selectively secure one or more boats300carried in the tray400so that the boats300are not free to move, vibrate, shake or rattle about within the tray400, for example, as the tray400is being moved, transported or otherwise handled, for example, by the robot112. That is to say, the clamping mechanisms410may be selectively employed to stabilize the boats300within the tray400when the tray400is being transported and/or otherwise handled, while still permitting suitable tolerances to exist, for example, between one or more inner dimensions of the receiving well or region402and one or more corresponding outer dimensions of the boat300.

The clamping mechanisms410, in some suitable embodiments, are arranged to automatically engage (i.e., secure boats300within the tray400) and automatically disengage (i.e., release boats300within the tray400) in response to and/or depending upon a position and/or state of the tray400. More specifically, as can be seen inFIG.5, when the tray400rests, resides in and/or is set upon one or more designated locations, for example, such as the turn table110or the buffer table114, the clamping mechanisms410are disengaged, i.e., the clamping mechanisms410do not actively hold the boats300or secure the boats300to the tray400. Conversely, as can be seen inFIG.4, when the tray400is removed from and/or does not reside in the designated locations, for example, when the tray400is lifted and/or removed from the turn table110and/or buffer table114to be transported and/or handled by the robot112, the clamping mechanisms410are engaged, i.e., the clamping mechanisms410do actively hold the boats300and secure the boats300to the tray400.

In some suitable embodiments, the turn table110has one or more posts or guide pins500thereon, for example, extending upward from a tabletop or surface where the tray400is selectively positioned and/or located when the tray400is resting or placed upon the turn table110. For illustrative purposes, inFIG.1, the turn table110is shown having 6 pins500, which correspond to the six clamping mechanisms410of the tray400. In practice, the turn table110may have more or less than 6 pins500. Suitably, the pins500are arranged on the turn table110so as to extend into, engage and/or cooperate with corresponding clamping mechanisms410to cause disengagement of the clamping mechanisms410when the tray400is placed and/or resides upon the turn table110(for example, as seen inFIG.5). Conversely, when the tray400is removed from and/or does not reside upon the turn table110(for example, as seen inFIG.4), the pins500are removed and/or disengaged from the clamping mechanisms410and/or no longer cooperating therewith, such that the clamping mechanisms410are free to transition into their engaged states, i.e., in which they hold and/or secure boats300to the tray400.

Likewise, the buffer table114may have one or more posts or guide pins500thereon, for example, extending upward from a tabletop or surface where the tray400is selectively positioned and/or located when the tray400is resting or placed upon the buffer table114. As with the turn table110, the pins500are arranged on the buffer table114suitably so as to extend into, engage and/or cooperate with corresponding clamping mechanisms410to cause disengagement of the clamping mechanisms410when the tray400is placed and/or resides upon the buffer table114. Conversely, when the tray400is removed from and/or does not reside upon the buffer table114, the pins500of the buffer table114are removed and/or disengaged from the clamping mechanisms410and/or no longer cooperating therewith, such that the clamping mechanisms410are free to transition to their engaged states, i.e., where they hold and/or secure boats300to the tray400. For illustrative purposes, inFIG.1, the buffer table114is shown having 6 pins500. In practice, the buffer table114may have more or less than 6 pins500.

FIG.3shows an exemplary clamping mechanism410in greater detail. Suitably, each clamping mechanism410includes a piston or plunger420having (i) a shaft422with a central axis Y extending in a horizontal or lateral direction and (ii) a boat-contacting head424arranged at a first end of the shaft422. The shaft422of the plunger420is suitably contained and/or arranged within a mechanism housing430such that the boat-contacting head424of the plunger420resides and/or extends outside the housing430. At or near a second end of the shaft422, opposite the first end, an annular lip or flange426may be arranged around the shaft422within the housing430. As shown, a coil spring440or other like biasing member (for example, without limitation, a leaf spring or other resiliently compressible and/or deformable member) is arranged and/or compressed between the flange426and a wall of the housing430, for example, so as to supply a mechanical force urging, biasing and/or pushing the plunger420along the Y axis in a direction of the plunger's head424which resides and/or extends outside of the housing430. Suitably, an annular ring432extending inward from the hosing430cooperates with the flange426to limit movement of the plunger420in the direction of the plunger's head424.

As shown, a pocket or notch428is also formed in the shaft422, for example, between the flange426and the head424of the plunger420. Suitably, the notch428has (i) a central vertical axis X, for example, which is substantially normal to the horizontal or lateral Y axis, and (ii) a sloped side wall or surface428a, for example, which extends at an angle θ with respect to the X axis. In some nonlimiting illustrative embodiments, the angle θ is in a range of between greater than or equal to about 20 degrees and less than or equal to about 70 degrees.

In some suitable embodiments, an opening is arranged and/or provided in the housing430to selectively receive therethrough a post or guide pin500. For example, the aforementioned opening in the housing430may be located on a bottom of the housing430. In some suitable embodiments, the pin500has a diameter Ø (for example, greater than or equal to about 2 mm in some nonlimiting illustrative embodiments) and a rounded or tapper end502(for example, distal from the turn table110and/or buffer table114from which the pin500extends) configured to contact and/or engage with the mated pocket or notch428formed in the shaft422as the clamping mechanism410and/or housing430is lowered over the pin500, for example, when the tray400is placed upon the turn table110or buffer table114(as shown inFIG.5). Conversely, when the clamping mechanism410and/or housing430is raised away from the pin500, for example, when the tray400is lifted off or removed from the turn table110or buffer table114by the robot112(as shown inFIG.4), the pin500is removed, withdrawn and/or disengages from the notch428.

FIG.4diagrammatically illustrates a clamping mechanism410in its engaged state, i.e., when the tray400is raised from and/or lifted off the turn table110such that a pin500extending from the turn table110is removed from the corresponding clamping mechanism410. More specifically, can be seen on one side ofFIG.4there is a top view of the tray400and on the other side ofFIG.4there is a cross section view of the region A.

Conversely,FIG.5diagrammatically illustrates a clamping mechanism410in its disengaged engaged state, i.e., when the tray400is positioned and/or resting atop the turn table110such that a pin500extending from the turn table110is inserted into the corresponding clamping mechanism410. More specifically, can be seen on one side ofFIG.5there is a top view of the tray400and on the other side ofFIG.5there is a cross section view of the region A.

With reference again toFIG.3, when the clamping mechanism410is in its engaged state as shown, the axis X of the notch428may be offset (for example, by some distance in a direction of the Y axis) from a central vertical axis X′ of the post500. Conversely, when the clamping mechanism is in the disengage state (as can be seen inFIG.5for example), the plunger420is withdrawn and/or retained by the post500being received in the notch428and so the axis X of the notch428and the axis X′ of the post500may substantially coincide in that case.

As shown inFIG.4, in practice, when the clamping mechanism410and/or housing430is raised away from the pin500so that the pin500is removed, withdrawn and/or disengaged from the notch428, the plunger420is free to move and/or extend, for example, along the Y axis, in the direction of the head424in accordance with the force imparted by the spring440, at least to a limit prescribed by the cooperation of and/or interaction between the annular ring432with the flange426. In this case, with the plunger420free to extend, the clamping mechanism410transitions into its engaged state. In some suitable embodiments, when the clamping mechanism410is in its engaged state, the boat300, residing within the receiving region402of the tray400, is pressed upon by the head424of the plunger420in accordance with the mechanical force supplied by the spring440, as opposed to when the clamping mechanism410is held in its disengaged state (see, for example,FIG.5), where the plunger420is withheld against the mechanical force imparted by the spring440, for example, by the pin500being engaged with the notch428, so that the head424of the plunger420does not press upon the boat300residing within the receiving region402of the tray400. In this way, the clamping mechanisms410transition between the engaged and disengaged states without a power supply for operating the clamping mechanisms included in the tray400. Rather, the driving force for operating the clamping mechanisms410is provided by the robotic or other automated placement or removal of the tray400onto or off a support such as the illustrative turn table110or buffer table114.

In some suitable embodiments, as seen inFIG.4, when a boat300resides with a receiving well or region402of the tray400, and the clamping mechanism410is in its engaged state (for example, because the tray400is lifted off and/or removed from the turn table110or buffer table114), the boat300is squeezed between the head424of the plunger420pressing thereupon and an opposing retaining wall or surface404of the tray400, for example, which retaining wall or surface404may extend substantially vertical from a base of the tray400. Conversely, as seen inFIG.5, when the clamping mechanism410is in its disengaged state (for example, because the tray400rests and/or resides on the turn table110or buffer table114), the plunger420is withheld against the mechanical force imparted by the spring440so that the head424of the plunger420does not press upon the boat300residing within the receiving well or region402of the tray400.

In accordance with some embodiments, as seen inFIG.2, the boats300may have a generally rectangular shape, i.e., including a first side304which shorter than a second side306. Suitably, when a boat is place within a receiving well or region402of the tray400, at least one clamping mechanism410(for example, nominally referred to as a first clamping mechanism and labeled with a corresponding primed reference numeral—i.e.,410′ inFIG.2) is arranged next to and/or along the first side304of the boat300and at least one other clamping mechanism410(for example, nominally referred to as a second clamping mechanism and labeled with a corresponding double primed reference numeral—i.e.,410″ inFIG.2) is arranged next to and/or along the second side306of the boat300.

Accordingly, when a boat300resides within the receiving well and/or region402of the tray400and the first clamping mechanism410′ is in its engaged state, the plunger head424of the first clamping mechanism410′ presses upon the first side304of the boat300, thereby squeezing the boat300between the plunger head424of the first clamping mechanism410′ and an opposing substantially vertical retaining surface and/or wall of the tray400. Likewise, when a boat300resides within the receiving well and/or region402of the tray400and the second clamping mechanism410″ is in its engaged state, the plunger head424of the second clamping mechanism410″ presses upon the second side306of the boat300, thereby squeezing the boat300between the plunger head424of the second clamping mechanism410″ and an opposing substantially vertical retaining surface and/or wall of the tray400.

Conversely, when a boat300resides within the receiving well and/or region402of the tray400and the first clamping mechanism410′ is in its disengaged state, the plunger head424of the first clamping mechanism410′ does not press upon the first side304of the boat300, such that the boat300is not squeezed between the plunger head424of the first clamping mechanism410′ and an opposing substantially vertical retaining surface and/or wall of the tray400. Likewise, when a boat300resides within the receiving well and/or region402of the tray400and the second clamping mechanism410″ is in its disengaged state, the plunger head424of the second clamping mechanism410″ does not press upon the second side306of the boat300, such that the boat300is not squeezed between the plunger head424of the second clamping mechanism410″ and an opposing substantially vertical retaining surface and/or wall of the tray400.

In some suitable embodiments, the first clamping mechanism401′ and the second clamping mechanism410″ are coordinated to automatically transition from their disengaged states to their engaged states in a designated non-simultaneous, sequential order, for example when the tray400is removed from the turn table110and/or buffer table114. In some suitable embodiments, the first clamping mechanism410′ transitions and/or begins transitioning to its engaged state before the second clamping mechanism410″ transitions and/or begins transitioning to its engaged state, for example when the tray400is lifted and/or removed from the turn table110and/or buffer table114by the robot122.

In some suitable embodiments, the order and/or timing in which the various clamping mechanisms410are automatically transitioned from their disengaged states to their engaged states is coordinated, regulated and/or controlled by suitably differentiating the diameters Ø of the posts500and/or the angles θ of the notches' sloped surfaces428a. For example, a diameter Ø1the post500corresponding to the first clamping mechanism410′ may be greater than a diameter Ø2the post500corresponding to the second clamping mechanism410″ and/or an angle θ1of the sloped surface428afor the notch428formed in the shaft422of the first clamping mechanism410′ may be greater than an angle θ2of the sloped surface428afor the notch428formed in the shaft422of the second clamping mechanism410″. Accordingly, when the tray400is lifted from the turn table110and/or buffer table114, the first clamping mechanism410′ transitions and/or begins to transition from its disengaged state to its engaged state prior to the second clamping mechanism410″ transitioning and/or beginning to transition from its disengaged state to its engaged state.

As can be appreciated, when the boat300is squeezed in a first direction against a retaining wall or surface of the tray400, friction therebetween resists movement of the boat300laterally with respect to the first direction. That friction is generally larger when a respective longer side of the boat300has a respective larger contact area with the retaining wall or surface of the tray400, as compared to the friction which results when a relatively shorter side of the boat300would have a relatively smaller contact area with the retaining wall or surface of the tray400. Accordingly, an advantage is achieved, by engaging the first clamping mechanism410′ arranged next to the shorter side304of the boat300prior to engaging the second clamping mechanism410″ arranged next to the longer side306of the boat300, since the second clamping mechanism410″ only has to overcome the relatively smaller friction produced by the relatively shorter side of the boat300being pressed into contact with the opposing retaining wall or surface, i.e., due to a relatively smaller contact area between by the relatively shorter side of the boat300and the retaining wall or surface of the tray400. In some suitable embodiments, the spring force of the spring440provided in the first clamping mechanism410′ may be different than the spring force of the spring440provided in the second clamping mechanism410″, for example, to accommodate the difference in friction between these two cases. In practice, for example, the spring force of the spring440provided in the first clamping mechanism410′ may be less than the spring force of the spring440provided in the second clamping mechanism410″.

As shown inFIG.6, in some suitable embodiments, the boats300and/or corresponding receiving wells and/or regions402of the tray400may have a generally polygonal shape other than generally rectangular. For example, where the shape of the boat300has an odd number of sides (for example, such as a triangle) and the retaining walls and/or surfaces404of the correspondingly shaped receiving well or region402meet at a corner406, a single clamping mechanism410may be arranged opposite that corner406and employed to selectively squeeze the boat300into that corner406. This has the advantage of not using multiple clamping mechanism410to selectively secure the boat300to the tray400. For simplicity, the single clamping mechanism410is not shown inFIG.6, rather the clamping action thereof is graphically represented by the arrow410a.

With reference now toFIG.7, there is shown a flow chart that illustrates a semiconductor device handling process600, for example, which may be carried out with the AMS100.

In a first step610, one or more boats300carrying more or more semiconductor devices are in turn selectively unloaded from the MLP100, for example, being sent into one or more of the conveyor lanes104to be transported there-along and/or thereby.

In a next step620, the grippers108may be moved along the linear table106toward an end of the conveyor lanes104where they retrieve the boats300therefrom.

In a next step630, the grippers108may be moved along the linear table106toward the turn table110where they deposit one or more boats300in a tray400residing or resting on the turn table110with the clamping mechanisms410of the tray400in their disengaged states as a result of the pins500on the turn table110extending into corresponding clamping mechanisms410.

In a next step640, the robot112lifts and/or otherwise removes the boat containing tray400from the turn table110. Accordingly, as the tray is lifted and/or removed from the turn table100, the posts and/or guide pins500thereon are removed from the clamping mechanisms410and as a result the clamping mechanisms410automatically transition from their disengaged states to their engaged states.

In the next step650, the robot112delivers the retrieved tray400to one of the process tool200or the buffer table114. In some suitable embodiments, when the tray400is delivered to the buffer table114, it is set down atop thereof, and accordingly, the posts and/or guide pins500of the buffer table114enter corresponding clamping mechanisms410of the tray400to thereby cause the clamping mechanisms410to automatically transition from their engaged states to their disengaged states.

In some embodiments, the operation of one or more of the various operable elements and/or components of the AHS100(for example, such as the MLP102, the conveyor lanes104, the linear table106, the grippers108and/or the robot112) is controlled, regulated and/or coordinated, for example, by a controller to carry out the process600and/or other suitable handling of the semiconductor device carrying boats300and/or the tray400. The controller may be implemented via hardware, software, firmware or a combination thereof. In particular, one or more controllers may be embodied by electronic processors (e.g. one or more microprocessors or microcontrollers), electrical circuits, computers and/or other electronic data processing devices that are configured and/or otherwise provisioned to perform one or more of the tasks, steps, processes, methods and/or functions described herein. For example, a processor, computer, server or other electronic data processing device embodying a controller may be provided, supplied and/or programmed with a suitable listing of code (e.g., such as source code, interpretive code, object code, directly executable code, and so forth) or other like instructions or software or firmware, such that when run and/or executed by the computer or other electronic data processing device one or more of the tasks, steps, processes, methods and/or functions described herein are completed or otherwise performed. Suitably, the listing of code or other like instructions or software or firmware is implemented as and/or recorded, stored, contained or included in and/or on a non-transitory computer and/or machine readable storage medium or media so as to be providable to and/or executable by the computer or other electronic data processing device. For example, suitable storage mediums and/or media can include but are not limited to: floppy disks, flexible disks, hard disks, magnetic tape, or any other magnetic storage medium or media, CD-ROM, DVD, optical disks, or any other optical medium or media, a RAM, a ROM, a PROM, an EPROM, a FLASH-EPROM, or other memory or chip or cartridge, or any other tangible medium or media from which a computer or machine or electronic data processing device can read and use. In essence, as used herein, non-transitory computer-readable and/or machine-readable mediums and/or media comprise all computer-readable and/or machine-readable mediums and/or media except for a transitory, propagating signal.

In general, any one or more of the particular tasks, steps, processes, methods, functions, elements and/or components described herein may be implemented on and/or embodiment in one or more general purpose computers, special purpose computer(s), a programmed microprocessor or microcontroller and peripheral integrated circuit elements, an ASIC or other integrated circuit, a digital signal processor, a hardwired electronic or logic circuit such as a discrete element circuit, a programmable logic device such as a PLD, PLA, FPGA, Graphical card CPU (GPU), or PAL, or the like. In general, any device, capable of implementing a finite state machine that is in turn capable of implementing the respective tasks, steps, processes, methods and/or functions described herein can be used.

In the following, some further illustrative embodiments are described.

In some embodiments, a tray of an automated handling system for transporting semiconductor devices is disclosed. The tray includes: a receiving region that is configured to receive a boat, the boat carrying one or more semiconductor devices thereon; and a clamping mechanism that selectively clamps the boat, residing in the receiving region, to the tray. Suitably, the clamping mechanism is automatically disengaged when the tray is positioned in a designated location and automatically engaged when the tray is not positioned in the designated location, such that, when engaged, the clamping mechanism holds the boat, residing in the boat receiving region, securely within the tray, and when disengaged, the clamping mechanism releases the boat residing in the boat receiving region.

In some further embodiments, the clamping mechanism includes: a movable plunger having a head at a first end thereof; and a biasing member which supplies a mechanical force that urges the plunger in a direction of the head. Suitably, when the clamping mechanism is engaged, the boat, residing within the receiving region of the tray, is pressed upon by the head of the plunger in accordance with the mechanical force supplied by the biasing member, and when the clamping mechanism is disengaged, the plunger is withheld against the mechanical force so that the head of the plunger does not press upon the boat residing within the receiving region of the tray.

In still additional embodiments, when the clamping mechanism is engaged, the boat, residing within the receiving region of the tray, is squeezed between the head of the plunger pressing thereupon and a surface of the tray.

In some embodiments, the biasing member is a spring.

In yet further embodiments, when the tray is positioned at the designated location, the clamping mechanism is held disengaged by a guide pin provided at the designated location, the guide pin cooperating with the clamping mechanism to withhold the plunger against the mechanical force of the biasing member so that the head of the plunger does not press upon the boat residing within the receiving region of the tray.

In some embodiments, the tray includes a plurality of the clamping mechanisms, and a first clamping mechanism of the plurality and a second clamping mechanism of the plurality are coordinated to engage in a non-simultaneous, sequential order when the tray is removed from the designated location.

In some further embodiments, the boat received in the receiving region of the tray has a first side and a second side; the first clamping mechanism is arranged along the first side of the boat when the boat resides in the receiving region and the second clamping member is arranged along the second side of the boat when the boat resides in the receiving region; and when the tray is removed from the designated location, the first clamping mechanism is engaged before the second clamping mechanism is engaged.

In some embodiments, the first side of the boat is shorter than the second side of the boat.

In yet further embodiments, an automated semiconductor device handling system includes: a boat carrying one or more semiconductor devices, the boat having a first side and a second side different than the first side; a table; a tray that is selectively positioned on the table; a first clamp arranged on the tray, said first clamp remaining in a disengaged state while the tray is positioned on the table; a gripper that selectively retrieves the boat and places the retrieved boat in the tray while the tray is positioned on the table with the first clamp in its disengaged state, the boat being placed in the tray by the gripper such that when the boat resides in the tray the first side of the boat is next to the first clamp; and a robot that selectively retrieves and removes the tray from the table with the boat residing in the tray. Suitably, when the tray with the boat residing therein is removed from the table by the robot, the first clamp automatically transitions from its disengaged state to an engaged state in which the first clamp applies a mechanical force that acts on the first side of the boat to hold the boat securely to the tray.

In some embodiments, the system further includes a first post extending from the table, such that when the tray is position on the table, the first post cooperates with the first clamp to hold the first clamp in its disengaged state, and when the tray is removed from the table the first post releases the clamp to automatically transition from its disengaged state to its engaged state.

In some further embodiments, the first clamp includes: a first movable plunger having a first shaft with a first head at one end thereof and a first notch formed in the first shaft, the first shaft extending along a first central axis and the first notch being formed about a second central axis extending normal to the first central axis of the first shaft, the first notch having a first sloped surface extending at a first angle with respect to the second central axis of the first notch; and a first spring that biases the first plunger in a direction of the first head. Suitably, when the tray is positioned on the table, the first pin cooperates with the first notch in the first shaft to withdraw the first plunger against the bias of the first spring in a direction away from the first head, and when the tray with the boat residing therein is removed from the table, the first pin is removed from the first notch in the first shaft thereby freeing the first plunger to act in accordance with the bias applied by the first spring so that the first clamp transitions into its engaged state in which the first head of the first plunger is pressed against the first side of the boat residing in the tray.

In still further embodiments, the system further includes: a second clamp arranged on the tray such that when the boat resides in the tray the second side of the boat is next to the second clamp, the second clamp remaining in a disengaged state while the tray is positioned on the table, and when the tray with the boat residing therein is removed from the table by the robot, the second clamp automatically transitions from its disengaged state to an engaged state in which the second clamp applies a mechanical force that acts on the second side of the boat to hold the boat securely to the tray; and a second post extending from the table, such that when the tray is position on the table, the second post cooperates with the second clamp to hold the second clamp in its disengaged state, and when the tray is removed from the table the second post releases the second clamp to automatically transition from its disengaged state to its engaged state. Suitably, the second clamp includes: a second movable plunger having a second shaft with a second head at one end thereof and a second notch formed in the second shaft, the second shaft extending along a third central axis and the second notch being formed about a fourth central axis extending normal to the third central axis of the second shaft, the second notch having a second sloped surface extending at a second angle with respect to the fourth central axis of the second notch; and a second spring that biases the second plunger in a direction of the second head. Suitably, when the tray is positioned on the table, the second pin cooperates with the second notch in the second shaft to withdraw the second plunger against the bias of the second spring in a direction away from the second head, and when the tray with the boat residing therein is removed from the table, the second pin is removed from the second notch in the second shaft thereby freeing the second plunger to act in accordance with the bias applied by the second spring so that the second clamp transitions into its engaged state in which the second head of the second plunger is pressed against the second side of the boat residing in the tray.

In yet additional embodiments, the first post has a first diameter and the second post has a second diameter, the first diameter being greater than the second diameter.

In some further embodiments, the first angle is greater than the second angle.

In some additional embodiments, the first clamp and the second clamp are coordinated to transition to their engage states in a non-simultaneous, sequential order when the tray is removed from the table by the robot.

In some embodiments, the first side of the boat is shorter than the second side of the boat and the first clamp transitions to its engaged state before the second clamp transitions to its engaged state when the tray is removed from the table by the robot.

In some embodiments, a first spring force of the first spring is less than a second spring force of the second spring.

In some further embodiments, a method of handling semiconductor devices includes: carrying a plurality of semiconductor devices in a boat having a first side and a second side different from the first side; resting a tray on a table, the tray having a first clamping mechanism and a second clamping mechanism arranged thereon which are automatically held, while the tray rests on the table, in disengaged states by first and second pins extending from the table, the first and second pins extending into the first and second clamping mechanisms while the tray rests on the table; placing the boat in the tray while the tray rests on the table such that the first side of the boat is next to the first clamping mechanism and the second side of the boat is next to the second clamping mechanism; and lifting the tray from the table with the boat in the tray. Suitably, when the tray is lifted from the table the first and second pins are removed from the first and second clamping mechanisms freeing the first and second clamping mechanisms to automatically transition from their disengaged states to engaged states in which the first clamping mechanism applies a first force to the first side of the boat and the second clamping mechanism applies a second force to a second side of the boat, thereby securing the boat to the tray.

In yet further embodiments, the first side of the boat is shorter than the second side of the boat; and when the tray is lifted from the table, the transition of first clamping mechanism from the disengage state to the engaged state begins before the transition of the second clamping from its disengaged state to its engaged state.

In still one more embodiment, the first force is applied by a first spring member included in the first clamping mechanism and the second force is applied by a second spring member included in the second clamping mechanism.