Narrow width loadport mechanism for cleanroom material transfer systems

A system and method of transporting substrates includes a loadport system including a frame, an articulating arm, a mini environment and a tower substantially centered in the frame. The tower includes multiple motors, a first motor mechanically coupled to the mini environment for moving the mini environment vertically. A second motors mechanically coupled to the articulating arm for moving the articulating arm vertically. A tower enclosure is also included. The tower enclosure enclosing the motors separate from the mini environment.

BACKGROUND

During semiconductor manufacturing, a semiconductor wafer undergoes a plurality of process steps, each of which are performed by a specialized process tool. Pods are used to convey semiconductor wafers from one tool to another. Each pod is capable of transporting a number of wafers of a specific diameter (e.g. 100-300 mm or larger). The pods are designed to maintain a protected internal environment to keep the wafers free of contamination, e.g., by particulates in the air outside the pod. Pods are also known for conveying other types of substrates, such as reticles, liquid crystal panels, rigid magnetic media for hard disk drives, solar cells, etc.

A loadport transfer device is defined to provide a standard mechanical interface (SMIF) to wafer fabrication production tools (process and/or metrology tools) to enable loading/unloading of pods into/out of wafer fabrication production tools, while ensuring protection of wafers therein from contamination.FIG. 1shows an articulation schematic of a conventional loadport10having a window12through which a pod14is moved, in accordance with the prior art. The conventional loadport10is defined to move the pod14through the window12in a Y direction, and is defined to move the pod14in a Z direction.

SUMMARY

Broadly speaking, the present invention fills these needs by providing a loadport capable of moving the pod in the vertical and horizontal directions. [note needs] It should be appreciated that the present invention can be implemented in numerous ways, including as a process, an apparatus, a system, computer readable media, or a device. Several inventive embodiments of the present invention are described below.

One embodiment provides a loadport system including a frame, an articulating arm, a mini environment and a tower substantially centered in the frame. The tower includes multiple motors, a first motor mechanically coupled to the mini environment for moving the mini environment vertically. A second motor mechanically coupled to the articulating arm for moving the articulating arm vertically. A tower enclosure is also included. The tower enclosure enclosing the motors separate from the mini environment.

The motors can be disposed between the mini environment and a base plate of the loadport, the base plate being coupled to the frame. The mini environment can include a filter assembly and a first fan coupled to the filter assembly for directing air though the filter assembly and into the mini environment. An inner volume of the mini environment can be a class 1 clean room environment. The tower enclosure can includes a second fan for drawing air out of the tower enclosure to an external environment. The second fan draws air through the second fan and out of the tower enclosure in a downward direction. The loadport can have a width substantially equal to a width of a substrate cassette location in a process tool.

The motors can include a third motor mechanically coupled to the articulating arm for moving the articulating arm horizontally away from the frame and toward a process tool. The articulating arm can include a gripper assembly. The gripper assembly can be a rotating gripper.

Another embodiment provides a substrate transport system including multiple loadport systems coupled to a process tool, the process tool having multiple substrate cassette locations. Each of the loadport systems includes a frame, an articulating arm, a mini environment and a tower substantially centered in the frame. The tower includes multiple motors. A first one of the motors is mechanically coupled to the mini environment for moving the mini environment vertically. A second one of the motors mechanically coupled to the articulating arm for moving the articulating arm vertically. A tower enclosure is also included. The tower enclosure enclosing the motors separate from the mini environment. Each one of the loadports is aligned with a corresponding one of the substrate cassette locations in the process tool. Each one of the loadports has a width substantially equal to a width of one of the substrate cassette locations.

Yet another embodiment provides a method of transporting substrates including aligning a loadport system with a corresponding one of multiple substrate cassette locations in a process tool. The loadport system including a frame, an articulating arm, a mini environment, a tower substantially centered in the frame. The tower includes multiple motors. A first one of the motors is mechanically coupled to the mini environment for moving the mini environment vertically. A second one of the motors is mechanically coupled to the articulating arm for moving the articulating arm vertically. A tower enclosure is also included in the loadport system. The tower enclosure encloses motors separate from the mini environment.

The loadport system can include multiple loadport systems and aligning the loadport system with one of the substrate cassette locations in a process tool can include aligning each one of the loadport systems with a corresponding one of the substrate cassette locations in the process tool.

The method can also include directing air though the filter assembly and into the mini environment. Air can also be drawn out of the tower enclosure to an external environment. An air pressure in the mini environment can be greater than an air pressure in the tower enclosure. Air can be drawn out of the tower enclosure to the external environment in a downward direction.

DETAILED DESCRIPTION

Several exemplary embodiments systems and methods of making and using a loadport capable of moving the pod in the vertical and horizontal directions will now be described. It will be apparent to those skilled in the art that the present invention may be practiced without some or all of the specific details set forth herein.

FIG. 2Ashows a substrate isolation container101in an open state, in accordance with embodiments of the present invention. The shell103of the substrate isolation container101is lifted away from the cassette105in the open configuration.FIG. 2Bshows the substrate isolation container in a closed state, in accordance with embodiments of the present invention. The shell103of the substrate isolation container101is placed over the cassette105and locked to the bottom door107in the closed configuration. The substrate isolation container101is defined to hold multiple substrates109in a secure manner while protecting the substrates109from contamination present outside of the substrate isolation container101. The substrate109can represent any type of article formed through the semiconductor fabrication process. For example, the substrate109may represent a semiconductor wafer, a flat panel display, a solar panel, among many others. For ease of description, the term substrate is used herein to refer to any type of article to be received into or retrieved from a semiconductor fabrication process tool or metrology tool.

The substrate isolation container101can be a standard mechanical interface (SMIF) pod including a cassette105within which the substrates109are held, a bottom door107to which the cassette105is connected, and a shell103defined to cover the cassette105and connect with the bottom door107.

FIG. 3Ashows an isometric view of the loadport200, in accordance with embodiments of the present invention.FIG. 3Bshows a loadport200, in accordance with embodiments of the present invention. The loadport200is shown with the mini environment1206in the lowered configuration inFIG. 3Aand a raised configuration, raised in direction351inFIG. 3B. Raising the mini environment1206also raises the outer shell103of the substrate isolation container101. Raising the mini environment1206also places the cassette105inside the mini environment to allow access to the cassette105by the process tool. When the mini environment is raised, a portion of the central tower1202can be seen.FIG. 3Cshows side view of the loadport200in the open configuration, in accordance with embodiments of the present invention. The loadport200provides a standard mechanical interface to wafer fabrication production tools, such as process and/or metrology tools, to enable loading of the cassette105from a transfer side201of the loadport200to a tool side203of the loadport200and to enable unloading of the cassette105from the tool side203of the loadport200to the transfer side201of the loadport200. It should be noted that the cassette105is shown with the enclosure103previously removed to simplify the following description.

The loadport200includes an isolation plate204that separates the transfer side201from the tool side203. The isolation plate204includes a window202. A retractable closure (not shown) can cover the window202when the loadport200is not conducting cassette105transfer operations. The retractable closure can uncover (e.g., open) the window202during cassette105transfer operations. For ease of discussion, the window202as depicted inFIG. 3Ais considered to be open to enable cassette105transfer operations. The loadport200moves the cassette105from a port plate306, through the window202, to a tool side stage307, vice-versa as described in more detail below.

The loadport200includes an articulating arm303for moving within a vertical plane oriented perpendicular to the window200. As shown inFIG. 3A, the vertical plane is the Y-Z plane as reference by coordinate axes300. It should be understood that the X direction of the coordinate axes300extends through the origin O perpendicular to both the Y and Z axes, i.e., the X direction extends perpendicularly through the paper upon whichFIG. 3Ais printed.

FIGS. 4A through 5show a sequence of loadport200operations for moving the cassette105from the port plate306to the tool side stage307.FIG. 4Ashows a Y-Z plane cross-section view of a starting state of the loadport200with the cassette105placed on the port plate306, in accordance with embodiments of the present invention. The arm carriage301and articulating arm303connected thereto are shown retracted downward along the Z axis into the loadport200.

FIG. 4Bshows a X-Z plane view A-A of the loadport200from the transfer side201, as referenced inFIG. 6A, in accordance with embodiments of the present invention. The cassette105placed on the port plate306is approximately centered upon a centerline601of the loadport200. The loadport can be offset slightly to one side of the centerline602to allow human or mechanical means to access the cassette105.

FIGS. 4C and 4Dare a flowchart diagram that illustrates the method operations420performed in moving the cassette from the transfer side201to the tool side203of the loadport200, in accordance with embodiments of the present invention. The operations illustrated herein are by way of example, as it should be understood that some operations may have sub-operations and in other instances, certain operations described herein may not be included in the illustrated operations. With this in mind, the method and operations420will now be described with reference toFIG. 5.

FIG. 5shows a Y-Z plane cross-section view of the loadport200moving to grasp the cassette105on the port plate306, in accordance with embodiments of the present invention. The loadport is shown inFIG. 5in the open configuration with the mini environment1206and the shell107fully removed to aid in clarity of discussion. It should be understood that the mini environment1206is actually still present during the following operations. In an operation422, the bottom door107of the substrate isolation container101is unlocked. The bottom door107can be unlocked by manual operation of by an automated unlocking system (not shown) that is included in the loadport. In an operation424, the mini environment1206and the port plate306are raised to raise the shell107as described above inFIGS. 2A-3C, thus enabling access to the substrates109in the cassette105in an operation430. In an optional operation432, the location of the substrates109and/or the cassette are mapped. Mapping the substrate109location of the cassette location can be accomplished by optical and other sensors included in the loadport or in the process tool side203.

In an operation434, the arm carriage301is moved vertically upward along the Z axis in a controlled manner, as indicated by arrow309. The articulating arm303is rotated in a controlled manner about the second rotational axis304, as indicated by arrow303, in an operation436. In an operation438, the gripper assembly305is moved into position as shown with the articulated arm in position550. In an operation440, the cassette is secured in the gripper assembly using the gripper latches2003as described in more detail below. In an operation442, the arm carriage301and the articulated arm assembly is moved downward along the Z axis while the articulated arm303is rotated about the second rotation axis304. The arm carriage301and the articulated arm assembly is moved downward along the Z axis to provide vertical clearance to move the cassette105and gripper assembly305through the window202as shown in position555. In an optional operation446, the spiral cam401is rotated in a controlled manner about the first rotational axis421, as indicated by arrow705. In an operation450, the arm carriage301and the articulated arm assembly is moved upward along the Z axis to increase the range of motion of the articulated arm303in the tool side203.

Included in the operations442-446above, the articulating arm303and the optional spiral cam401may optionally be rotated in a coordinated manner so as to secure the substrates within the cassette105in position555. By way of example, the cassette105may be angled relative to the Y axis such that the substrates cannot slide out of the cassette105as the cassette105is transported from the transfer side201to the tool side203. The cassette105may be angled at an angle θ. Angle θ can be between a very narrow angle (e.g., less than about 10 degrees) or as much as fully perpendicular to the Y axis.

In an operation452the articulating arm303is further rotated about the second rotational axis304to extend the articulated arm into the tool side203. Optionally, the spiral cam can also be rotated in an operation454as the articulating arm303is further rotated about the second rotational axis304to maintain the desired angle θ.

For one reason or another, (e.g., width of the loadports200A-200D) it may not be possible to place the loadports200A-200D in relative alignment to the centerlines of the corresponding tool side stages. In an optional operation456, the cassette is displaced horizontally along the X axis, perpendicular to the cassette location centerline on the tool side203. Optional operation456can occur simultaneously with one or more of the above operations442-454.

By way of example, if the centerline of the loadport is aligned with the centerline of the tool side stage. Therefore, horizontal displacement of the cassette along the X axis as it is moved between the loadport and the tool side stage is not necessary. In this case, the loadport can be equipped with a gripper assembly305directly connected to the rotatable shaft419.

The loadport can be equipped with a right-handed spiral cam apparatus400to provide for horizontal displacement of the cassette to the left along the X axis, as it is moved between the loadport and the tool side stage307. The loadport can be equipped with a right-handed spiral cam apparatus to provide for horizontal displacement of the cassette to the left along the X axis, as it is moved between the loadport and the tool side stage307. The loadport can be equipped with a left-handed spiral cam apparatus to provide for horizontal displacement of the cassette to the right along the X axis as it is moved between the loadport and the tool side stage. Considering the above example, it should be appreciated that use of the spiral cam apparatus400can significantly improve efficiency in fabrication facility floor planning and space utilization.

In an operation458, the articulating arm303continues to rotate in a controlled manner about the second rotational axis304, as indicated by arrow313and the optional spiral cam401can continue to rotate in a controlled manner about the first rotational axis421, as indicated by arrow313, until the cassette105has reached the desired drop off position stop along the Y Axis. In an operation460, the cassette105is lowered into the drop off position until the cassette has been detected on the tool side203stage307in an operation462. The gripper305releases the latches2003to release the cassette105in an operation464. In an operation466the articulating arm303can return to a home position. In an operation468, the mini environment1206returns to a home (e.g., lowered) position and the method operations can then end.

FIG. 6shows two typical loadports1101A-B in a tandem arrangement with a multiple loadlocks1102A-D of typical 200 mm open cassette process tool1100. As discussed above, the typical loadports1101A-B are too wide to mechanically align with the respective centerlines of many typical 200 mm and smaller, loadlocks1102A-D on many processing tools.

By way of example, some early process tool loadlocks1102A-D had narrow chambers openings between 254 mm (10″) and 305 mm (12″). Two standard width LPTs1101A-B mounted side by side have a minimum distance center to center is 355 mm (14 inches). Likewise, many early 200 mm open cassette process tools1100have center to center cassette distances of between about 279 mm to about 342 mm (about 11 to about 13.5 inches). Thus, as shown inFIG. 11, there is insufficient space for typical loadports1101A-B in a side by side configuration on many 200 mm open cassette process tools1100. This prevents loading/unloading cassettes from all four tracks1102A-D. As a result, the throughput of the process tool1100is substantially restricted and reduced to a less than optimum throughput volume.

The typical LPT1101A-B for transferring 200 mm cassettes from SMIF-pods to process and metrology tool cassette stations has an overall width that prevents full utilization of tool throughput capacity for tools such as a photoresist track and a vertical furnace that have closely spaced cassettes. The typical LPT1101A-B has a width of about 430 mm (about 17 inches) and the minimum cassette spacing using a dedicated left/right pair of typical LPTs is about 355 mm (about 14 inches) from centerline to centerline with an overall width for both units of about 860 mm (about 34 inches) or more. The LPTN1201A can support a cassette-to-cassette centerline spacing of about 245 mm (9.5 inches). The LPTN1201is slightly wider (e.g., functionally wider, e.g., about 5-20% wider than the substrate isolation container101) so as to provide access for human or mechanical means to access and manipulate the substrates within the cassette105within the substrate isolation container101.

FIG. 7Ais a front view of a narrowed loadport (LPTN)1201A, in accordance with embodiments of the present invention.FIG. 7Bis front view of a typical loadport (LPT)1101A.FIG. 8Ais a perspective view of a narrowed loadport (LPTN)1201A, in accordance with embodiments of the present invention.FIG. 8Bis a perspective view of a typical loadport (LPT)1101A.FIG. 9Ais a top view of a narrowed loadport (LPTN)1201A, in accordance with embodiments of the present invention.FIG. 9Bis top view of a typical loadport (LPT)1101A.

FIGS. 10A-11Billustrate additional views of the LPTN1201A, in accordance with embodiments of the present invention. The LPTN1201A has relocated the motors and actuating hardware from the side1104of the typical loadport1101A to a tower enclosure1202more closely aligned to the centerline of the LPTN. The tower enclosure1202is located beneath the port plate306and can optionally be closely aligned to the centerline of the loadport. In one embodiment, the tower enclosure1202is beneath the plane of the port plate306but not necessarily aligned to the centerline of the loadport. The tower enclosure1202is enclosed within the mini environment1206to reduce the width of the LPTN1201A and reduce the volume of the mini environment1206. The port plate1420includes an access door1153so that the port plate1420can lift the shell103of the substrate isolation container101and allow the bottom door107of the substrate isolation container101to pass through the door1153as the port plate1420lifts the shell103.

The respective width and architectural arrangement of the LPTN1201A and the typical LPT1101A is shown for comparison purposes. The typical LPT1101A has motors and actuating hardware1104mounted on the side of the typical LPT. In contrast, the LPTN1201A has located the motors and actuating hardware to a tower1202enclosure more closely aligned to the centerline of the LPTN.

The LPTN1201A increases the throughput on multi-cassette process tools (e.g., process tool1100). The LPTN1201A architecture enables cassette transfer to tools that have multiple load stations (two or more) where the use of a left/right pair of typical LPTs1101A-B (e.g., as shown inFIG. 11) prevents use of all the loadports1102A-D.

A typical V-move LPT1101A loading/unloading cycle time is approximately 55 seconds. The LPTN1201A architecture also reduces cassette loading/unloading cycle time. The LPTN1201A architecture substantially eliminates or at least minimizes the need for left/right mirror image LPTs. Left/right mirror image LPTs require differing component configurations and extra component inventory and more complex manufacturing schedule allowances. The LPTN1201A can use a standard LPT-XR software. The TR unit has its own Teach Pendant w/programmable functions separate from LPTN1201A.

The LPTN1201A architecture significantly reduces the loadport width and footprint while maintaining the cleanliness, reliability, and flexibility attributes that have defined the typical LPT1101A as the tool interface of choice in virtually all 200 mm processing fabs.

The smaller footprint of the LPTN1201A is achieved by locating the vertical lift assemblies for the cassette transfer mechanisms and the mini environment into a centrally located, sealed tower1202. The tower1202is located beneath the base plate306which supports the substrate isolation container101(e.g., SMIF-Pod). The tower1202may or may not be substantially aligned with a centerline of the loadport1201A. However, the tower1202is contained within the width or footprint (width×depth) of the substrate isolation container101and thus this approach enables a loadport width that is 125 mm narrower than the typical loadport1101A. The LPTN1201A also includes a height reduction of about 75 mm as compared to the typical loadport1101A. The LPTN1201A also has a lower center of gravity that enhances and maintains stability even with smaller footprint.

The mini environment cleanliness is improved due to a smaller mini environment volume and enhanced sealing. The LPTN1201A also includes full compatibility with many existing options and recent developments of the typical loadport1101A. The LPTN1201A can also remain fully compatible with current loadport interface software and control options.

Reliability, service, support for the LPTN1201is assured by re-use of many motion control and electro-mechanical components, including servo motors for the mini environment and cassette transfer assemblies, CPU and servo drive electronics and class 1 Fan/ULPA filter assembly.

The LPTN1201A is also compatible with existing teach pendant (and teaching methodology). The construction materials for LPTN1201A mini environment, frame, and port plate are also substantially the similar to typical loadports1101A.

The LPTN1201A can use many common components with the typical loadport1101A including a harmonic drive gearbox assembly including gripper tilt and sensor functions, articulating arm303with gripper shaft and bearings, gripper assembly305including associated clamps, cassette fingers, and cabling, CPU and servo drive electronics plus the indexer board and associated mapping sensors, window202and isolation plate204with latchkey drive, fan/filter unit for the mini environment, AC power supply, operator control interface/switches on mini environment housing, power rail Z lift components for the transfer arm assembly and the mini environment (e.g., motors, bearings. Etc.). Operating software including profile moves, error detection, tool communication and operator teach pendant and associated control algorithms and diagnostics can also be substantially common between a typical LPT and an LPTN1201A.

The LPTN1201A also includes many new innovations not included in the typical LPT1101A. The LPTN1201A frame base plate includes wheels/shafts and leveling screws. The frame side plates can be 10 mm thick×100 mm wide aluminum plates. The port plate perimeter frame can include re-positioned laser mapper optics. The linear motion tower1202includes dual Z drive ball slide and lead screw assemblies and motors1208A-D in the centerline of the LPTN1201A. The LPTN1201A mini environment shell1206is somewhat based on current design but the new design of the LPTN allows the mini environment to be narrower and shorter and thus have a significantly smaller volume. The smaller volume mini environment shell1206allows increased and simpler control of the mini environment.

The mounting and routing for the linear motion flex cables are also different than in the typical LPT1101A. The separator panel between the mini environment1206and the transfer arm is also updated. The mounting element attaching the gearbox to the Z-drive tower is a new design as the motor locations have been moved from the side of the typical LPT1101A to the bottom of the LPTN1201A.

The top cap tie-plate joining the two side rails is also improved. Plex isolation plates are added to the mini environment. A removable access cover for the linear motion tower is included.

All of the above innovations address the need for a smaller footprint loadport. Two side-by-side LPTNs1201A can remain in the boundaries of a narrow process tools. LPTNs1201A are able to access some narrow space applications without the need for additional options (e.g., horizontal motion equipment options). The LPTN1201A reuses many existing major components and provide improved operating speed without wafer vibration. The same kinematic mounting, same operating functions, same options and configurations are also included in the LPTN1201A. The LPTN1201A allows both loadports to remain within the footprint boundary of the process tool. Further, LPTN1201A control is more accessible and less obstructed than with typical LPT1101A.

LPTN1201A is configured for ergonomically transferring substrates contained in cassettes. The cassettes, in embodiments are defined for enclosure in standard mechanical interface (SMIF) pods. Generically, a loadport is a port used to transfer semiconductor substrates, or other types of substrates between one environment and another environment. Typically, the environments are between a clean room environment and a more controlled environment near, in, or proximate to a processing tool. A processing tool should be broadly construed to include any processing tool used in the manufacture of an end product.

The end product can include semi-conductor devices, flat-panel devices, radical devices used in photolithography, and can include any size of the substrate. In semi-conductor processing, semiconductor devices are manufactured from silicon substrates, such as wafers. As is well known, the wafers can be defined in various sizes. Typical sizes include 100 mm, 150 mm, 200 mm, 300 mm, 450 mm, etc.

Depending on the size of the substrate, the SMIF pod (e.g., cassette105) is constructed to contain and support various numbers of substrates, in a stacked orientation inside of the cassette resident inside the SMIF pod. A SMIF pod is configured for automated opening and closing in a fabrication facility (e.g., to enable substrate access and/or cassette access), and can also be moved from place to place within a fabrication facility by a human or mechanical device. When substrates need to be transferred between the SMIF pod (e.g., substrate isolation container101) and a processing tool, the loadport provides the interface. In a fabrication environment, loadports are connected to tools by way of bolts, interfaces, and other coupling mechanisms. The loadports are configured to receive SMIF pods on a port assembly. The loadport is configured to separate the outer shell of the SMIF pod while retaining the cassette within a mini environment of the loadport. The LPTN1201A, in accordance with embodiments of the present invention, includes the mini environment structure1206that moves vertically along a Z axis while removing the outer shell103of the SMIF pod.

Once the mini environment1206is in a raised orientation, the articulating arm303assembly with a gripper assembly305that is part of the LPTN1201A is configured to access the cassette105from the port assembly and move the cassette into an environment of the tool. As noted above, the tool can take on various configurations, depending on the fabrication operations being performed. The tool can be, for instance, an etching system, an equipment front and module (EFEM), a loadlock, a process tool, a deposition tool, a robot, a shelf, a storage staging location, a stocker, a vehicle, metrology tools, or any other fabrication facility destination that receives the cassette from the LPTN1201A.

FIG. 10Ashows a frame1401of the LPTN1201A, in accordance with embodiments of the present invention. The frame1401is configured to be connected to a tool interface. The tool interface can be in the form of a wall, a Box Opener/Loader-to-Tool Standard Interface (BOLTS) structure or similar structure for LPTN1201A frame1401, an EFEM interface, or the processing tool itself. The frame1401of the LPTN1201A has a vertical construction near the interface of the LPTN and the tool interface. As shown inFIG. 14A, the LPTN1201A includes a mini environment shell1206that is configured to move in a vertical direction along the Z axis along the frame1401.

The tower1202is enclosed within the mini environment1206. The tower1202can enclose various components of the LPTN1201A. In one embodiment, located within the tower1202is a dual Z drive system that is configured to raise the mini environment1206when access to the cassette105(and substrates109within) is desired, and also provide mechanical motor assistance to a articulated arm303that accesses the cassette and delivers the cassette to the process tool. In this embodiment, the drive system is a dual system because it is configured with one system for raising and lowering the mini environment and another system for providing the mechanical assistance to the transfer arm that handles transport of cassettes between the LPTN1201A and the process tool. The

FIG. 10Billustrates a side view of an LPTN frame1401without the mini environment shell1206. The mini environment shell1206is not shown to allow viewing of the tower enclosure1202which encloses the dual Z drive mechanisms in an isolated region to prevent particle contamination from being exposed near the port assembly where substrates will be present.

In one embodiment, a first fan1402is provided connected to a filter assembly1404that is contained within the mini environment shell1206. The first fan1402is configured to push air from the clean room in through the fan into the filter assembly1404and up in a direction toward the port assembly. The filter assembly1404can also move in the vertical direction toward the port assembly along with the mini environment shell1206. Although not shown, when the mini environment shell1206is in the up position, the filter assembly1404will be located just below the port assembly, but still contained within the mini environment. As such, clean air is then pushed into the mini environment1206where the cassette105will be located once the shell103of the SMIF pod101is raised.

A second fan1403is contained within the tower enclosure1202near a lower region. The second fan1403draws air out of the tower enclosure1202where the Z drive mechanisms are located. The second fan1403draws air in a vertical direction toward the floor where the LPTN1201A is configured to sit. As such, the first fan1402will draw air into the mini environment1206through the filter assembly1404in the vertical direction upward, while the second fan1403will draw air away from the mini environment1206toward the floor and substantially creating a flow of air within the tower enclosure1202removing any particulates produced by the motors and driving them away from regions where substrates will be present.

FIG. 11Aillustrates another cross-sectional isometric view of the frame1401of the LPTN1201A, in accordance with embodiments of the present invention. This illustration shows the location of an indexer PCB assembly1415that is located near the bottom region of the LPTN1201A. The indexer PCB assembly1415includes multiple electronic components that will dictate movement of the LPTN1201A. As noted above, the movement of the LPTN1201A includes movement of the mini environment shell1206upward and downward along the Z axis depending on the state of operation. Additional coordination provided by the circuitry of the indexer PCB assembly1415is to control the movements of the multiple sections of the articulating arm303that accesses the cassette105and transfers the cassette between the transfer side201of the LPTN1201and the tool side203. The filter assembly1404is coupled to a portion of the frame1401that couples to one of the Z drive motors1208A.

The filter assembly1404can move in the vertical direction between the lower position illustrated inFIG. 11Aand an upper position that is just below the window202.FIG. 11Ashows the mini environment shell1206removed so as to illustrate components of the LPTN1201A. In this view, the tower enclosure1202is shown located below the port assembly1420. Locating the Z drive assembly below the port assembly1420, and in a location that is substantially centered in the frame1401of the LPTN1201A, it is possible to reduce the width of the LPTN to only the frame components. In this embodiment, motors and drives necessary to move the mini environment shell and the transfer arm are no longer coupled to a side frame structure as in typical LPT1101A, but are now located in a center region of the LPTN1201A. The center of gravity of the LPTN1201A can thereby be more centered on the tool structure, preventing possible tendencies of tilt during movements of the LPTN1201A within a fabrication facility.

Additionally, by placing the drive motors1208A-D in the center region, covered by the tower enclosure1202, it is possible to place the moving parts away from the port assembly1420where cassettes are to be placed. Additionally, the tower enclosure1202having the second fan1403can isolate particle generation to a region that is below the port assembly1420. The typical LPT1101A places the drive mechanisms on the sidewall and thus the width of the typical LPT1101A is significantly wider than the LPTN1201A.

Additionally, having motors and drives on the sidewalls of a typical LPT1101A, particle generation is also potentially placed in closer proximity to semiconductor substrates when the open cassette105is exposed inside the mini environment shell1206. As noted above, the port assembly1402is configured to remain fixed to the LPTN1201A while the mini environment shell1206moves up and down to create the mini environment when in the up position and when the outer shell103of the SMIF pod has been opened.

The drive mechanism for the articulating arm303, although not shown inFIG. 14Cin its complete configuration, is also provided with the drive from the motors contained within the tower enclosure1202located under the port assembly1420.

FIG. 11Billustrates an isometric rear view of the LPTN1201A, when exposed to illustrate components, in accordance with embodiments of the present invention. In this example, the power supply1410is shown located in the rear lower section of the LPTN1410. The I/O board1411is also located near the rear lower section where the rear of the LPTN1201A is the side of the LPTN adjacent to the process tool side203. The I/O board couples to the indexer PCB assembly1415and electronics. The I/O board1411typically includes the plugs, and interfaced connections for coupling the LPTN1201A to a data network, tool interface wiring, connections, power and to provide indicators for diagnostic equipment and to communicate with software during programming or to access software stored on chips, hard drives, memory, storage, or other circuitry and processors located on the LPTN1201A. In this embodiment, the LPTN1201A is also provided with data networking interfaces to allow connection of the LPTN to a data network, for determining status, set rules, set programming, said operational parameters, and to retrieve diagnostics associated with use, and service routines. The CPU1412is also shown located near the rear lower section of the LPTN1201A.

The harmonic drive1413is located in the midsection of the LPTN1201A. The harmonic drive1413includes driving mechanisms for communicating and directing a vertical orientation of the articulating arm303, and translating motion information to the articulating arm303. The motion information is provided to the various segments of the articulating arm303, including the gripper assembly305. In one embodiment, multiple pulleys, chains or coupling interfaces are provided to the articulating arm303and articulating arm303segments through the harmonic drive1413. The harmonic drive1413is in communication with the CPU1412, so as to define the program motions of the articulating arm303and interfacing with the process tool.

FIGS. 12A and 12Bare detailed views of the lower portion of the LPTN1201A, in accordance with embodiments of the present invention.FIGS. 13A-14Dprovide various additional views of the LPTN1201A, in accordance with embodiments of the present invention. The LPTN1201A includes a pair of rear wheels1423and a pair of front wheels1424. The placement of the wheels1423,1424can vary, depending on the configuration and as shown in the various figures disclosed herein. The mini environment shell1206linear bracket1421provides the vertical motion of the filter assembly1404when coupled to the mini environment shell1206(not shown).

A tape roller seal1422seals a path slot1425defined in the sidewalls of the mini environment1206. The path slot1425is required to allow the mini environment shell1206to be raised and lowered. The tape contains particulates that may be produced within the tower enclosure1202and exhausted downward using the second fan1403.

As there are two motors contained within the tower enclosure1202, there will be two slots on each side of the tower enclosure1202. This will allow for the brackets to move up and down to raise and lower the mini environment shell1206and also provide the up and down movement of the motor that provides motion for the articulating arm303.

A first motor1208A raises and lowers the mini environment shell1206and a second motor1208B raises and lowers the arm carriage301and the articulating arm303. Both motors1208A,1208B are placed in the center lower region of the LPTN1201A inside the tower enclosure1202. Placing the motors1208A,1208B in the center lower region of the LPTN1201A lowers and centers the center the gravity of the LPTN. This lower, more centered center of gravity of the LPTN1201A provides additional stability and thus prevents accidental tipping of the LPTN during movement within a fabrication facility.

When the mini environment shell1206is in a raised position1206′ as shown inFIG. 14B, the SMIF pod shell103is also raised to a raised position103′, exposing the cassette105and wafers contained within the mini environment. The filter assembly1404can be connected to the lower portion of the mini environment shell1206and can be raised in conjunction with the mini environment shell. When the mini environment shell1206is raised, and the cassette105will be exposed, but the filter assembly1404will be pushing clean, filtered air in a vertical direction from below and adjacent to the port assembly1420, while the open cassette105is present in the mini environment shell1206and while the articulating arm303and the gripper assembly305accesses the cassette105for movement into the process tool.

Process tools are often configured to receive multiple cassettes105in line. The multiple cassettes105can be delivered by multiple typical LPTs1101A connected side-by-side to the front face of a specific process tool. However, as described above, if the typical LPT1101A is too wide (e.g., not sufficiently narrow) and due to the mechanisms mounted on the typical LPT side frame will not allow the maximum number of typical LPTs to be connected to the process tool. In one specific example, a process tool can be configured to have four tool side stages307so as to be able to receive four cassettes105at one time. If the spacing between the four tool side stages307is narrow, it will not be possible for four typical LPTs to be connected to the front face of the process tool, as all four typical LPTs cannot deliver to the four tool side stages307.

The narrower construction of the LPTN1201A allows four LPTNs to be used in parallel to simultaneously deliver four multiple cassettes105to the corresponding four tool side stages307when the pitch between the locations is narrow (as defined by the process tool interface parameters).

The articulating arm303of an LPTN1201A can include a spiral cam401connected to one end of the articulating arm. The end of the articulating arm303can be the location where the gripper assembly305is coupled to the articulating arm. The spiral cam401can provide direction positioning of the cassette105when the cassette is placed into the tool side stage307of the process tool. Thus, if the location of the cassette105targeted within the process tool is a narrow pitch, one or more LPTNs1201A with spiral cams401can be placed side-by-side to increase the capability of delivering cassettes105to the tool side stages307within the process tool.

FIGS. 15A-Jillustrate various views of two LPTNs1201A,1201B in a tandem, side by side configuration, in accordance with embodiments of the present invention. two LPTNs1201A,1201B in a side by side configuration can be used for a process tool203that has two loadlocks or similar loading locations1102A,1102B. The two LPTNs1201A,1201B used in side by side configuration can have articulating arm303on the same sides (e.g., both on the right or both on the left, not shown) or on opposite sides as shown.

FIGS. 15B and 15Cillustrate the articulating arm303moving cassettes105into the process tool203. As shown inFIG. 15Dthe LPTNs1201A,1201B articulating arms303move the cassettes105to locations1102A,1102B that are about 310 mm center to center. Also shown inFIG. 15Dthe side by side configuration LPTNs are aligned with the centerline of the desired cassette locations in the process tool. As shown inFIG. 15E, the articulating arm303can move the cassettes105up to about 280 mm into the process tool203. The articulating arms303can move the cassettes105less or more reach into the process tools203.

FIGS. 16A-16Dillustrate three LPTNs1201A,1201B,1201D used in side by side and single configuration, in accordance with embodiments of the present invention. The three LPTNs1201A,1201B,1201D transport cassettes105into a process tool203that has three or more loadlocks or similar loading locations1102A-D. As shown inFIG. 16Ceach of the LPTNs1201A,1201B,1201D are aligned with the centerline of the corresponding cassette locations1102A-D in the process tool203. This increases the throughput of the process tool203approximately 50% as compared to using only two typical LPTs1101A,1101B as shown above inFIG. 11.

FIGS. 17A-17Eillustrate four LPTNs1201A,1201B,1201C,1201D used in four side by side configuration, in accordance with embodiments of the present invention. The four LPTNs1201A,1201B,1201C,1201D used in four side by side configuration to transport cassettes105into a process tool203that has four loadlocks or similar loading locations1101A,1101B,1101C,1101D.

As shown inFIG. 17Deach of the LPTNs1201A,1201B,1201C,1201D are aligned with the centerline of the corresponding cassette locations1101A,1101B,1101C,1101D in the process tool203. This increases the throughput of the process tool approximately 100% as compared to using only two typical LPTs1101A,1101B as shown above inFIG. 11.

FIGS. 18A-18Cillustrate various configurations of the base plate1810, in accordance with embodiments of the present invention. The various configurations of the base plate1810illustrates several possible configurations of the wheels1423,1424therein. As shown inFIG. 18Athe outer wheels1424are shown having a relatively wide track having a width T being widely separated and very near the respective corners of the base plate1801.

As shown inFIGS. 18B and 18Can optional location for the outer wheels1424′ and1424″, respectively, that are configured with a relatively narrow track having a width T′ (e.g., wheels are closely spaced side by side), where width T′ is less than width T and thus the outer wheels1424′ and1424″ are located near the centerline1802of the base plate1801. As shown inFIG. 18Couter wheels1424″ can include three or more wheels.

The inner wheels1423on the opposite edge of the base plate1801have a substantially wider track T″ as the inner wheels are more closely located near their respective corners. This configuration gives the base plate a near tricycle or three-point contact with the surface. Thus the three-point surface contact can provide more stability for the LPTN1201A if the surface is uneven. The three-point surface contact can also simplify leveling the LPTN1201A on an uneven surface.

FIGS. 19A-19Billustrate an alternate embodiment of the LPTN1201A′, in accordance with embodiments of the present invention. The alternate embodiment of the LPTN1201A′ includes a single Z axis drive1902in place of the dual Z axis drive in the LPTN1201A. The single Z axis drive1902is somewhat simpler and requires on a single Z axis drive mechanism. The drive components within the tower1202can raise and lower the mini environment and/or provide the motivation to the articulated arm assembly. As shown inFIG. 19Athe drive components within the tower1202are coupled to the articulated arm assembly for operating the articulated arm. The articulated arm assembly includes the components301-305as described above. The drive components within the tower1202can also raise and lower the mini environment1206as described above. However it should be understood that an external system could move the min environment to open the substrate isolation container101and access the substrates109therein. It should also be understood that some process tools may include a robot or other articulated arm that can access the cassette105and/or the substrates109therein directly from the LPTN1201A thus rendering one or more of the drive assemblies in the tower1202as being redundant and unnecessary.

FIGS. 20A-20Lillustrate various configurations of the articulating arm303and the gripper assemblies305, in accordance with embodiments of the present invention. The various configurations of the articulating arm303and the gripper assemblies305, can be used for left and right optional configurations. The articulating arm303and the gripper assemblies305can enable rotation of the cassette105in more than one axis (e.g., pitch and yaw). The articulating arm303is coupled to and moved by a dual axis harmonic drive gearbox assembly.

The rotating gripper305′ head addresses the need to deliver cassettes105angled receiving stages up to 65 degrees or more (e.g. up to about 90 degrees). The rotating gripper305′ includes a pivot2002, and an articulating arm extension2001. The rotating gripper305′ also includes gripper clamps2003on each end of the gripper. The rotating gripper305′ also includes motors2021,2022for rotating the gripper305′ about the pivot2002. A main gear2010is mechanically coupled to the pivot2002. Motor2021rotates a worm gear2020that is meshed with the main gear2010, or other precise rotation means (e.g., a belt or cam driven means). And thus causes the rotating gripper305′ to rotate relative to the pivot2002. Circuit boards2011and2012provide the controls for the motors2021,2022and the gripper clamps2003and feedback (e.g., location and grip sensing) data. Circuit boards2011and2012also provide a data interface to the LPTN1201A.

A new generation loadport narrow (LPTN) comprising: a mini environment includes a first fan that forces air though a filter into the mini environment; the inner volume of the mini environment can be a class 1 clean room environment; a tower is included inside the mini environment; the tower includes a second fan drawing air out of the tower and out to the external environment; The tower also includes a plurality of motors, gears, shafts, chains, etc. for moving the mini environment vertically and for operating a transfer arm, multiple movable joints within the transfer arm, and a gripper on the end of the transfer arm; an air flow path includes flowing in through the first fan, through the filter into the mini environment and then into the tower where air is drawn out by the second fan; the tower is included proximate to the bottom portion of the mini environment and substantially centered on a delivery side of the mini environment; the mini environment is held on a frame; the mini environment and the frame have a first width only slightly wider than a width of the “pod” (SMIF, FOUP, etc.) to be delivered; the first diameter is about 12.9 inches (328 mm) for a pod for supporting and transporting substrates having a diameter of about 200 mm; the frame includes a support side that supports the mini environment and allows the mini environment to traverse vertically; the frame also includes a delivery side opposing the support side; the delivery side of the frame can be coupled to any desired processing tool, the first width of the mini environment and frame allows the LPTN to be aligned with correspondingly narrow loading positions on a process tool. Further, multiple (two-four or more) LPTNs can be coupled side by side and aligned to multiple loading positions in a process tool having multiple loading positions; the frame is connected to a base; the secondary enclosure is secured to the base; the base can include three or four wheels on a bottom surface of the base; the three or four wheels can be arranged such that a first two wheels have a first track width and are proximate to a first edge of the base; if only three wheels are used, the third wheel can substantially be centered on the opposing edge of the bottom surface of the base; if four wheels are used, the second 2 wheels can have a second track that is narrower than the first track and the second 2 wheels can substantially be centered on the opposing edge of the bottom surface of the base; the transfer arm can be on the left or the right edge of the delivery side of the frame; the transfer arm can include a gripper; the gripper can rotate in at least 1 axis on the end of the transfer arm; the gripper can rotate in 1-3 axes on the end of the transfer arm.

An advantage of the LPTN architecture using the vertical drive/guiding mechanism approximately under the centerline of the SMIF Pod is that not only is the unit much narrower, but the mechanism for the left and right versions is almost identical.

The invention can also be embodied as computer readable code on a computer readable medium. The computer readable medium is any data storage device that can store data, which can thereafter be read by a computer system. Examples of the computer readable medium include hard drives, network attached storage (NAS), read-only memory, random-access memory, CD-ROMs, CD-Rs, CD-RWs, DVDs, Flash, magnetic tapes, and other optical and non-optical data storage devices (e.g., smart tags RF ID communication and other radio or wireless identification systems). The computer readable medium can also be distributed over a network coupled computer systems so that the computer readable code is stored and executed in a distributed fashion.

It will be further appreciated that the instructions represented by the operations in the above figures are not required to be performed in the order illustrated, and that all the processing represented by the operations may not be necessary to practice the invention. Further, the processes described in any of the above figures can also be implemented in software stored in any one of or combinations of the RAM, the ROM, or the hard disk drive.