Stocker apparatus and substrate treating apparatus

A stocker apparatus and method have openers for receiving FOUPs acting as containers each for storing a plurality of substrates, to feed and collect the substrates to/from a substrate treating apparatus main body, a transport mechanism for holding and transporting the FOUPs, and racks arranged above the openers for receiving the FOUPs. The racks include an incoming rack for receiving the FOUPs from an external transport device, an outgoing rack for delivering the FOUPs to the external transport device, and a mid-treatment storage rack for keeping an empty FOUP after the substrates are fed therefrom. The openers include a feed-only opener for feeding the substrates, and a collect-only opener for collecting the substrates.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

This invention relates to a stocker apparatus and a substrate treating apparatus for storing substrates such as semiconductor wafers, glass substrates for photo resist, glass substrates for liquid crystal displays, or substrates for optical disks (hereinafter called simply “substrates”).

(2) Description of the Related Art

A conventional substrate treating apparatus of the single substrate type, as shown inFIG. 1, includes an indexer mechanism100, four openers101a-101dand treating units (not shown). The openers101a,101b,101c, . . . , when not distinguished, will be referred to as “opener(s)101”.

Each opener101receives, on a support table, a FOUP (Front Opening Unified Pod) F which is a container storing a plurality of substrates in multiple stages in a substantially horizontal state, and opens and closes a lid of the FOUP F. When the lid of the FOUP F is opened by the opener101, the indexer mechanism100transports the substrates from the FOUP F to treating units.

In recent years, the substrate treating apparatus has been constructed to include an increased number of treating units which are stacked in multiple layers, to improve throughput of the substrate treating apparatus. The number of openers101installed has also been increased correspondingly. However, as shown inFIG. 2, the openers101simply juxtaposed in one row will increase the width of the substrate treating apparatus in the direction of X-axis in which the openers101are juxtaposed. This enlarges an installation area of the substrate treating apparatus.

Then, the following technique has been proposed (e.g. in Japanese Unexamined Patent Publication No. 2000-124301).

This substrate treating apparatus includes a cassette table for receiving carrier cassettes each storing a plurality of substrates, and an auxiliary arm for loading and unloading the substrates into/from the carrier cassettes. Between the cassette table and auxiliary arm, a container is provided for storing the carrier cassettes in two, upper and lower stages. This container is movable up and down.

A carrier cassette placed on the cassette table is first transported to one of the two stages of the container. The auxiliary arm takes the substrates out of the carrier cassette transported into the container. When all the substrates have been taken out, the carrier cassette now empty is displaced by vertical movement of the container.

By vertical movement of the container, a next carrier cassette placed on the cassette table and storing substrates to be treated can be transported to the other stage of the container. Subsequently, the auxiliary arm can take the substrates out of the carrier cassette transported to the other stage of the container.

Such construction including the container and cassette table can store (keep) two carrier cassettes in the container. Where, for example, four of this construction are juxtaposed, a maximum of eight carrier cassettes can be stored. Therefore, enlargement of the apparatus can be inhibited while being capable of receiving an increased number of carrier cassettes.

A FOUP station (stocker apparatus) has been disclosed as an apparatus similar to the above and capable of receiving many FOUPs (e.g. Japanese Unexamined Patent Publication No. 2005-150495).

In this apparatus, a mechanism for transporting FOUPs F can feed many substrates to a substrate treating apparatus by transporting a FOUP F made empty of substrates to a different location, and transporting another FOUP F storing substrates to be treated to a transfer position to feed the substrates from this FOUP F.

The conventional apparatus with such a construction has the following drawback.

The substrates having received a predetermined treatment cannot be collected unless the mechanism for transporting FOUPs F puts an empty FOUP F on standby on an opener beforehand for substrate collection. When, for example, a delay occurs in transporting the empty FOUP for use in collecting substrates, a resulting standby time will impair efficient collection. A smooth operation is difficult without rules determined beforehand for transporting empty FOUPs F and collecting treated substrates.

SUMMARY OF THE INVENTION

This invention has been made having regard to the state of the art noted above, and its object is to provide a stocker apparatus and a substrate treating apparatus capable of feeding and collecting substrates efficiently while inhibiting enlargement of the apparatus.

The above object is fulfilled, according to this invention, by a stocker apparatus connected to a single substrate type substrate treating apparatus main body, comprising openers for receiving FOUPs acting as containers each for storing a plurality of substrates, to feed and collect the substrates to/from the substrate treating apparatus main body; a transport mechanism for holding and transporting the FOUPs; a control device for controlling at least FOUP transport; and racks arranged above the openers for receiving the FOUPs, and including an incoming rack for receiving the FOUPs from an external transport device; an outgoing rack for delivering the FOUPs to the external transport device; and a mid-treatment storage rack for keeping an empty FOUP after the substrates are fed therefrom; the openers including a feed-only opener for feeding the substrates, and a collect-only opener for collecting the substrates.

According to this invention, the openers for receiving FOUPs to feed and collect the substrates include a feed-only opener and a collect-only opener for separate uses. The feed-only opener is used only for feeding substrates from inside each FOUP, while the collect-only opener is used only for collecting the substrates into each FOUP. The transport mechanism transports an empty FOUP after the substrates are fed therefrom, from the feed-only opener to the collect-only opener, and then places a next FOUP storing substrates to be treated on the feed-only opener. This enables a continued operation to feed the substrates from the FOUPs. The collect-only opener receives the empty FOUP to collect treated substrates successively. After the treated substrates have been collected, the transport mechanism transports the FOUP storing the treated substrates from the collect-only opener to the outgoing rack, and places a next empty FOUP on the collect-only opener. This enables a continued operation to collect the substrates into the FOUPs. That is, the feed-only opener and collect-only opener are used to feed and collect substrates in succession, thereby realizing efficient feeding and collection of the substrates.

With the mid-treatment storage rack provided, when an empty FOUP after the substrates are fed therefrom is transported from the feed-only opener to the collect-only opener, but the empty FOUP cannot be transported to the collect-only opener because of presence thereon of a different FOUP, the empty FOUP can be transported to the mid-treatment storage rack. This allows a next FOUP storing substrates to be treated, to be placed on the feed-only opener, and therefore the substrates can continue to be fed from this FOUP. That is, since a FOUP can be transported to the mid-treatment storage rack even when the FOUP cannot be transported from the feed-only opener to the collect-only opener, substrates can be fed and collected continually without interruption.

An empty FOUP after the substrates are fed therefrom can be kept on the mid-treatment storage rack. Since it is not necessary to increase the number of openers, as is necessary with a conventional apparatus, the width of the apparatus can be maintained.

Further, the racks include, for separate uses, an incoming rack for receiving the FOUPs from an external transport device, and an outgoing rack for delivering the FOUPs to the external transport device. This allows the FOUPs to be transferred to and from the external transport device efficiently.

The above construction can feed and collect the substrates efficiently, and can inhibit enlargement of the apparatus compared with the conventional apparatus constructed by increasing the openers in one row.

In the above invention, it is preferred that the control device is arranged, when the empty FOUP after the substrates are fed therefrom is unable to be transported to the collect-only opener because of a different FOUP present on the collect-only opener, to cause the empty FOUP to be transported to the mid-treatment storage rack. When the empty FOUP after the substrates are fed therefrom is transported from the feed-only opener to the collect-only opener, but the FOUP cannot be placed on the collect-only opener because of presence thereon of a different FOUP, the control device causes the empty FOUP to be transported to the mid-treatment storage rack. This allows a next FOUP storing substrates to be treated, to be placed on the feed-only opener from which the empty FOUP has been transported, and therefore the substrates can continue to be fed from the next FOUP.

In the above invention, it is preferred that the racks further include a pre-treatment storage rack for keeping a FOUP storing substrates to be treated. With the pre-treatment storage rack provided, when a FOUP storing substrates to be treated is transported from the incoming rack to the feed-only opener, but the FOUP cannot be transported to the feed-only opener because of presence thereon of a different FOUP, the new FOUP can be kept on the pre-treatment storage rack. This allows a next FOUP storing substrates to be treated, to be placed on the incoming rack. An increased number of FOUPs storing substrates to be treated can be kept in the apparatus.

In the above invention, it is preferred that the racks further include a post-treatment storage rack for keeping a FOUP storing treated substrates. With the post-treatment storage rack provided, when a FOUP storing treated substrates is transported from the collect-only opener to the outgoing rack, but the FOUP cannot be transported to the outgoing rack because of presence thereon of a different FOUP, the FOUP storing treated substrates can be kept on the post-treatment storage rack. This allows a next empty FOUP to be placed on the collect-only opener. An increased number of FOUPs storing treated substrates can be kept in the apparatus.

In the above invention, it is preferred that the control device is arranged, when a FOUP placed on the incoming rack is unable to be transported to the feed-only opener because of a different FOUP present on the feed-only opener, to cause the FOUP placed on the incoming rack to be transported to the pre-treatment storage rack. When a FOUP placed on the incoming rack and storing substrates to be treated cannot be transported to the feed-only opener because of a different FOUP present on the feed-only opener, the control device causes this new FOUP to be transported to the pre-treatment storage rack. This allows the external transport device to transport a next FOUP storing substrates to be treated to the incoming rack from which the preceding FOUP has been transported.

In the above invention, it is preferred that the control device is arranged, when a FOUP having collected the substrates is unable to be transported to the outgoing rack because of a different FOUP present on the outgoing rack, to cause the FOUP having collected the substrates to be transported to the post-treatment storage rack. When a FOUP having collected the substrates is unable to be transported to the outgoing rack because of a different FOUP present on the outgoing rack, the control device causes the FOUP having collected the substrates to be transported to the post-treatment storage rack. This allows a next empty FOUP to be transported to the collect-only opener from which the preceding FOUP has been transported, whereby the substrates continue to be collected in the FOUPs.

In the above invention, it is preferred that each of the racks has a mechanism for opening and closing horizontally right and left, the mechanism in an open state allowing a FOUP to move vertically. Each rack having the mechanism for opening and closing horizontally right and left, when opened, permits vertical movement of a FOUP, and when closed, can hold the FOUP. This can reduce the size in the longitudinal direction of the stocker apparatus, thereby to inhibit enlargement of the apparatus.

In the above invention, it is preferred that the transport mechanism is movable horizontally and vertically as opposed to the openers and the racks, and is arranged to rotate about a vertical axis after drawing near a FOUP to be transported, thereby supporting the FOUP in a position directly above a horizontal transport path, and to move horizontally and vertically in this state to transport the FOUP to a predetermined position. The transport mechanism is movable horizontally and vertically as opposed to the openers and the racks, and is arranged to rotate about a vertical axis after drawing near a FOUP to be transported, thereby supporting the FOUP in a position directly above a horizontal transport path, and to move horizontally and vertically in this state to transport the FOUP to a predetermined position. This can reduce the size in the longitudinal direction of the stocker apparatus, thereby to inhibit enlargement of the apparatus.

In another aspect of the invention, a substrate treating apparatus comprises a single substrate type substrate treating apparatus main body for performing a predetermined treatment of substrates; and a stocker apparatus connected to the substrate treating apparatus main body; the stocker apparatus including openers for receiving FOUPs acting as containers each for storing a plurality of substrates, to feed and collect the substrates to/from the substrate treating apparatus main body; a transport mechanism for holding and transporting the FOUPs; a control device for controlling at least FOUP transport; and racks arranged above the openers for receiving the FOUPs, and including an incoming rack for receiving the FOUPs from an external transport device; an outgoing rack for delivering the FOUPs to the external transport device; and a mid-treatment storage rack for keeping an empty FOUP after the substrates are fed therefrom; the openers including a feed-only opener for feeding the substrates, and a collect-only opener for collecting the substrates.

According to this invention, the stocker apparatus is provided which includes openers for receiving FOUPs to feed and collect substrates, racks for receiving the FOUPs, and a transport mechanism capable of transporting the FOUPs. This construction can inhibit enlargement of the apparatus compared with the conventional apparatus constructed by increasing the openers in one row.

The openers of the stocker apparatus include a feed-only opener and a collect-only opener for separate uses. The feed-only opener is used only for feeding substrates from inside each FOUP, while the collect-only opener is used only for collecting substrates into each FOUP. An empty FOUP after the substrates are fed therefrom is transported from the feed-only opener to the collect-only opener, and then the feed-only opener receives a next FOUP storing substrates to be treated. This enables a continued operation to feed the substrates from the FOUPs. The collect-only opener receives the empty FOUP to collect treated substrates successively. After the treated substrates have been collected, the FOUP storing the treated substrates is transported to the outgoing rack, whereby a next empty FOUP can be placed on the collect-only opener. This enables a continued operation to collect the substrates into the FOUP. That is, the substrates can be fed and collected in succession, thereby realizing efficient feeding and collection of the substrates.

With the mid-treatment storage rack provided, when an empty FOUP after the substrates are fed therefrom is transported from the feed-only opener to the collect-only opener, but the empty FOUP cannot be transported to the collect-only opener because of presence thereon of a different FOUP, the empty FOUP can be transported to the mid-treatment storage rack. This allows a next FOUP storing substrates to be treated, to be placed on the feed-only opener, and therefore the substrates can continue to be fed from this FOUP. That is, since a FOUP can be transported to the mid-treatment storage rack even when the FOUP cannot be transported to the collect-only opener, substrates can be fed and collected continually without interruption.

Further, an incoming rack for receiving the FOUPs from an external transport device, and an outgoing rack for delivering the FOUPs to the external transport device, are provided for separate uses. This allows the FOUPs to be transferred to and from the external transport device efficiently.

Thus, the substrates can be fed and collected efficiently, and enlargement of the apparatus can be inhibited compared with the conventional apparatus constructed by increasing the openers in one row.

In the above invention, it is preferred that the control device is arranged to control the transport mechanism to execute a first transport step for transporting a FOUP placed on the incoming rack to the feed-only opener; a second-A transport step for transporting the FOUP placed on the feed-only opener and made empty of the substrates to the collect-only opener; a second-B transport step for once transporting the FOUP placed on the feed-only opener and made empty of the substrates to the mid-treatment storage rack to be kept thereon, and transporting the FOUP in keeping to the collect-only opener; and a third transport step for transporting the FOUP placed on the collect-only opener and having collected the substrates to the outgoing rack. The control device controls the transport mechanism to transport a FOUP placed on the incoming rack to the feed-only opener. The substrates are fed from the FOUP transported to the feed-only opener, and after the substrates are fed, the empty FOUP is transported to the collect-only opener. When the empty FOUP cannot be transported to the collect-only opener because of a different FOUP present thereon, the empty FOUP is once transported to the mid-treatment storage rack to be kept thereon, and is thereafter transported to the collect-only opener. Treated substrates are collected successively into the FOUP placed on the collect-only opener. After the substrates have been collected, the FOUP is transported from the collect-only opener to the outgoing rack. In this way, the substrates can be fed and collected efficiently.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

A preferred embodiment of this invention will be described in detail hereinafter with reference to the drawings.

Embodiment

FIG. 3is a fragmentary side view in vertical section of a substrate treating apparatus with a stocker apparatus according to an embodiment of this invention.FIG. 4is a section taken on line A-A of the stocker apparatus shown inFIG. 3.FIG. 5is a section taken on line B-B of the substrate treating apparatus with the stocker apparatus shown inFIG. 3.

As shown inFIG. 3, the substrate treating apparatus includes a substrate treating apparatus main body1of the single-substrate type, and a stocker apparatus2installed as connected to the substrate treating apparatus main body1. The substrate treating apparatus main body1includes an indexer block3, a treating block4and an interface block5interconnected in order from the left side of the stocker apparatus2inFIG. 3.

This indexer mechanism7takes wafers W out of a FOUP F set to an opener10of the stocker apparatus2, and transports the wafers W to receiving trays8disposed between the indexer block3and treating block4. The receiving trays8are arranged at respective stages of the treating block4having a layered structure, and are used for transfer of wafers W between the indexer block3and treating block4. When treated wafers W are placed on the receiving trays8, the indexer mechanism7transports the wafers W from the receiving trays8into FOUPs F.

The treating block4includes treating units, not shown, such as coating units for applying photoresist, chemical treating units for treatment with a developer and heat-treating units in a vertically stacked arrangement. The treating block4includes also transport mechanisms, not shown, for transporting wafers W to and from the respective treating units.

The interface block5includes a transport mechanism, not shown, for transferring wafers W between the substrate treating apparatus and an external apparatus6(e.g. an exposing apparatus) juxtaposed with the substrate treating apparatus.

The stocker apparatus2includes, arranged in a plane adjoining the indexer block3, openers10for receiving FOUPs F, each being a container for storing a plurality of wafers W in multiple stages, in order to deliver and receive wafers W from/into the FOUPs F, and racks20for receiving and keeping the FOUPs F. The stocker apparatus2further includes a transport mechanism30for holding and transporting the FOUPs F.

Each opener10has a shutter unit (not shown) for opening and closing a lid of a FOUP F placed on the support table of the opener10, and opening and closing a passage port formed in a partition between the stocker apparatus2and indexer block3. The indexer mechanism7fetches and deposits wafers W from/in the FOUP F whose lid has been opened by this shutter unit. A plurality of openers10are juxtaposed as described hereinafter, and will be indicated as “10a,10b,10c,10d, . . . ” when the openers10are distinguished.

A FOUP F transported by the transport mechanism30passes through a space SP1between the openers10/racks20and the transport mechanism30, and freely moves horizontally and vertically (XZ plane inFIG. 3).

As shown inFIG. 4, the stocker apparatus2has four openers10a-10darranged in juxtaposition. These openers10a-10dhave different roles to play, such that the two left openers10aand10bare used exclusively for feeding wafers W, and the two right openers10cand10dfor collecting wafers W. The racks20are arranged above these openers10a-10d.

The racks20are used individually for different purposes, and include two mid-treatment storage racks BF1and BF2(hereinafter referred to as mid-treatment storage racks BF when the mid-treatment storage racks BF1and BF2are not distinguished) for receiving and keeping empty FOUPs F after wafers W are fed from the FOUPs F, one pre-treatment storage rack BFB for keeping a FOUP F storing wafers W to be treated, and one post-treatment storage rack BFA for keeping a FOUP F storing treated wafers W. The racks20further include an incoming rack21used to receive FOUPs F storing wafers W to be treated from an external transport device40, and an outgoing rack22used to deliver FOUPs F storing treated wafers W to the external transport device40.

As shown inFIG. 4, the pre-treatment storage rack BFB, mid-treatment storage racks BF1and BF2and post-treatment storage rack BFA are arranged in the stated order from left to right above the openers10a-10d. The incoming rack21is located above the pre-treatment storage rack BFB, and the outgoing rack22above the post-treatment storage rack BFA.

A housing60providing outer peripheral walls for this stocker apparatus2covers the bottom and the sides, and opens at the top. Through this top opening, the external transport device40, shown inFIG. 6, transports and places FOUPs F on the incoming rack21, receives FOUPs F from the outgoing rack22, and transports the FOUPs F to an apparatus at the next stage, for example.

[Construction of Transport Mechanism30]

As shown inFIG. 5, the transport mechanism30includes a gripper31for gripping an upper portion of each FOUP F, and an articulated arm mechanism32connected to the gripper31for moving the gripper31back and forth. The articulated arm mechanism32is supported at a proximal end thereof by a support block33. The support block33is movable by a first moving mechanism34along the direction of juxtaposition of the openers10a-10d, that is along the direction of width (X-axis) of the stocker apparatus. This first moving mechanism34is vertically movable (along Z-axis) by a pair of second moving mechanisms35. Consequently, the transport mechanism30can transport each FOUP F freely to positions of the openers10and racks20.

Specifically, the transport mechanism30transports each FOUP F as follows. The articulated arm mechanism32advances the gripper31, which grips and fixes the upper portion of a FOUP F placed on one of the openers10or racks20. Then, the gripper31raises the FOUP F, and is moved back to position the FOUP F in the space SP1. The first moving mechanism34and second moving mechanisms35are operated to move the FOUP F within the space SP1to a position opposed to a predetermined opener10or rack20. Subsequently, the articulated arm mechanism32advances the gripper31to place the FOUP F on the predetermined opener10or rack20. The gripper31is opened and moved back to complete the transport of the FOUP F.

Transfer of FOUPs F between the external transport device40and stocker apparatus2will be described with reference toFIG. 6.

The external transport device40is a device which transports FOUPs F between the substrate treating apparatus in this embodiment and an external apparatus separate from this apparatus. In this embodiment, an OHT (Over head Hoist Transport) will be described by way of example.

The external transport device40includes a rail48laid in an overhead location such as a ceiling in a factory, and transport vehicles41guided by the rail48to transport FOUPs F. Each transport vehicle41has a gripper42for gripping and supporting a FOUP F, ropes43suspending the gripper42gripping the FOUP F, and a winch, not shown, for winding and unwinding the ropes43to move the FOUP F up and down.

A transport vehicle41transporting a FOUP F, when arriving at a location above a predetermined position for depositing the FOUP F (e.g. the incoming rack21), lowers the FOUP F in suspension, and when the lowering is completed, causes the gripper41fixedly holding the FOUP F to release the FOUP F, thereby depositing the FOUP F in place.

The left transport vehicle41inFIG. 6is engaged in an operation for placing a FOUP F on the incoming rack21. The right transport vehicle41has received a FOUP F from the outgoing rack22, and is about to transport the FOUP F to the next apparatus.

FIG. 7is a block diagram of a control system relating to the transport of FOUPs F in the external transport device40and the substrate treating apparatus in this embodiment.

First, as shown inFIG. 7, the stocker apparatus2has a controller83of its own independently of a main controller82of the substrate treating apparatus. This controller83controls the transport of FOUPs F by the transport mechanism30, and the opening and closing of the lids of the FOUPs F placed on the openers10(FIG. 3). On the other hand, the main controller82of the substrate treating apparatus carries out an overall control of the stocker apparatus2and others.

The controller83of the stocker apparatus2is constructed capable of communication with the main controllers82of the substrate treating apparatus. The main controller82of the substrate treating apparatus is constructed capable of communication with a central controller81of the factory which controls production of the entire factory.

The central controller81of the factory which controls production of the entire factory is constructed capable of communication with a transport controller84of the external transport device40.

The main controller82of the substrate treating apparatus transmits and receives information to/from the controller83of the stocker apparatus2, and acts as a relay for transferring information transmitted from the controller83of the stocker apparatus2to the central controller81of the factory, for example.

The controller83of the stocker apparatus2corresponds to the control device in this invention.

Next, the transfer of FOUPs F to and from the external transport device40will be described with reference toFIGS. 6 and 7.

When requesting transport of a FOUP F to the incoming rack21of the stocker apparatus2, for example, the controller83of the stocker apparatus2transmits to the main controller82of the substrate treating apparatus information requesting transport of a FOUP F storing wafers W to be treated. The main controller82of the substrate treating apparatus transfers the request information to the central controller81of the factory. Based on the request information, the central controller81of the factory instructs the transport controller84of the external transport device40to transport a FOUP F storing wafers W to be treated to the incoming rack21of the stocker apparatus2. Thus, the external transport device40transports a FOUP F storing wafers W to be treated to the incoming rack21of the stocker apparatus2, and places the FOUP F thereon.

In the above description, the information requesting transport of a FOUP F is transmitted from the controller83of the stocker apparatus2to the central controller81of the factory through the main controller82of the substrate treating apparatus. However, the information requesting transport of a FOUP F may be transmitted from the controller83of the stocker apparatus2to the central controller81of the factory through the transport controller84of the external transport device40.

In the above description, the main controller82of the substrate treating apparatus carries out an overall control of the stocker apparatus2and others, while the controller83of the stocker apparatus2itself controls the transport of FOUPs F. However, the main controller82of the substrate treating apparatus may directly supervise the controller83of the stocker apparatus2, and control the transport of FOUPs F through this controller83.

With this arrangement, for example, the main controller82of the substrate treating apparatus receives information from the controller83of the stocker apparatus2that the incoming rack21is vacant, and based on this information, transmits information requesting transport of a FOUP F to the central controller81of the factory.

[Operation of the Stocker Apparatus]

Next, operation of the stocker apparatus2will be described with reference toFIGS. 8 through 12.

FIG. 8is a flow chart of operation of the stocker apparatus2.FIGS. 9A-9Kare explanatory view of transport of a plurality of FOUPs F within the stocker apparatus2.FIGS. 10 through 12are explanatory views illustrating the effect of the stocker apparatus2according to the embodiment.

<Description of Operation by the Flow Chart>

First, operation will be described with reference to the flow chart ofFIG. 8.

This flow chart shows what determinations are made to transport one FOUP F from the time this FOUP F is placed on the incoming rack21in the stocker apparatus2until the same FOUP F is placed on the outgoing rack22. The operation described hereinafter takes place in the stocker apparatus2having the construction shown inFIG. 4.

The external transport device40transports a FOUP F to the incoming rack21and places the FOUP F thereon.

When the FOUP F has been placed on the incoming rack21, it is determined first whether the feed-only openers10aand10bare vacant (available for transport or not). Specifically, sensors, not shown, provided for the openers10aand10bdetect presence or absence of FOUPs F, whereby the controller83determines whether the openers10aand10bare vacant. When the openers10aand10bare vacant (available for transport), the FOUP F is transported to one of the openers10aand10b. When, for example, only the opener10ais vacant, the FOUP F is transported from the incoming rack21to the opener10a. When both are vacant, priority may be given to the opener10afor placement.

When neither of the feed-only openers10aand10bis vacant (that is, when transport is impossible because other FOUPs are present thereon), it is determined next whether the pre-treatment storage rack BFB is vacant. The controller83makes this determination based on a detection signal from a sensor, not shown, provided for the pre-treatment storage rack BFB as in the case of the openers10aand10bnoted above. Such determination technique is the same with the other openers10cand10dand other racks20, and its description will be omitted hereinafter. When the pre-treatment storage rack BFB is vacant, the FOUP F is transported from the incoming rack21to the pre-treatment storage rack BFB. When the pre-treatment storage rack BFB is occupied, the FOUP F is kept on standby on the incoming rack21until the pre-treatment storage rack BFB becomes vacant.

When the pre-treatment storage rack BFB is vacant, the transport mechanism30transports the FOUP F to the pre-treatment storage rack BFB.

For the FOUP F placed on the pre-treatment storage rack BFB, it is determined whether the feed-only openers10aor10bis vacant. When vacant, the FOUP F is transported from the pre-treatment storage rack BFB to the vacant opener10aor10b. When not vacant, the FOUP F remains on standby in the same position (on the pre-treatment storage rack BFB) until either one of the openers10aand10bbecomes vacant.

When one of the openers10aand10bis vacant, the transport mechanism30transports the FOUP F to the vacant opener10aor10b. The opener10aor10bopens the lid of the FOUP F, and the indexer mechanism7feeds the wafers W successively into the substrate treating apparatus.

After the feeding of the wafers W from the FOUP F is completed by the indexer mechanism7, it is determined whether the collect-only opener10cor10dis vacant. When vacant, the FOUP F now empty of wafers W is transported from the opener10aor10bhaving finished feeding the wafers W to the vacant opener10cor10d. When, for example, both openers10cand10dare vacant, priority may be given to the opener10cfor placement.

When neither of the collect-only openers10cand10dis vacant, it is determined next whether the mid-treatment storage rack BF1or BF2is vacant. When vacant, the empty FOUP F is transported from the feed-only opener10aor10bto the vacant one of the mid-treatment storage racks BF1or BF2. When both are vacant, for example, priority may be given to the mid-treatment storage rack BF1for placement. When not vacant, the FOUP F remains on standby on the opener10aor10bhaving finished feeding the wafers W until one of the mid-treatment storage rack BF1or BF2becomes vacant.

When either one of the mid-treatment storage racks BF1or BF2is vacant, the transport mechanism30transports the empty FOUP F to the vacant mid-treatment storage rack BF1or BF2.

After the FOUP F is placed on the mid-treatment storage rack BF1or BF2, it is determined whether one of the collect-only openers10cand10dis vacant. When vacant, the FOUP F is transported from the mid-treatment storage rack BF1or BF2to the vacant collect-only opener10cor10d. When both the mid-treatment storage racks BF1and BF2are loaded at this time, the FOUP F deposited earlier of the two FOUPs is transported to the vacant collect-only opener10cor10d. When not vacant, the FOUP F remains on standby in the same position (on the mid-treatment storage rack BF1or BF2) until either one of the openers10cand10dbecomes vacant.

When one of the collect-only openers10cor10dis vacant, the empty FOUP F is transported to the vacant collect-only opener10cor10d.

At the opener10cor10dhaving received the empty FOUP F, the indexer mechanism7successively deposits in the FOUP F wafers W having received the predetermined treatment. After the wafers W are collected, the opener10cor10dcloses the lid of the FOUP F.

After the wafers W are collected in the FOUP F, it is determined whether the outgoing rack22is vacant. When vacant, the FOUP F storing the treated wafers W is transported to the outgoing rack22from the opener10cor10dhaving finished collecting the wafers W.

When the outgoing rack22is not vacant, it is determined next whether the post-treatment storage rack BFA is vacant. When vacant, the FOUP F storing the treated wafers W is transported from the collect-only opener10cor10dto the post-treatment storage rack BFA. When not vacant, the FOUP F remains on standby in the same position (on the collect-only opener10cor10d) until the post-treatment storage rack BFA becomes vacant.

When the post-treatment storage rack BFA is vacant, the transport mechanism30transports the FOUP F to the post-treatment storage rack BFA.

After the FOUP F is placed on the post-treatment storage rack BFA, it is determined whether the outgoing rack22is vacant. When vacant, the FOUP F storing the treated wafers W is transported from the post-treatment storage rack BFA to the outgoing rack22. When not vacant, the FOUP F remains on standby in the same position (on the post-treatment storage rack BFA) until the outgoing rack22becomes vacant.

When the outgoing rack22is vacant, the transport mechanism30transports the FOUP F to the outgoing rack22. Then, the FOUP F stands by in that position until it is transported to the next apparatus by the external transport device40.

As described above, attention has been paid to one FOUP F in the flow chart shown inFIG. 8, and the FOUP F is transported in the stocker apparatus2based on various determinations. However, in an actual situation, a plurality of FOUPs F move one after another in the stocker apparatus2. Operation will be described hereinafter for transporting a plurality of FOUPs F in the stocker apparatus2.

<Operation for Transporting a Plurality of FOUPs F within the Stocker Apparatus>

Next, how a plurality of FOUPs F are transported successively based on the flow chart shown inFIG. 8will be described with reference toFIGS. 9A through 9K. Here, the FOUPs F will be indicated with numbers affixed thereto as “FOUPs1,2, . . . ” in the order of transport by the external transport device40.

InFIG. 9A, FOUP1is transported to the incoming rack21by the external transport device40.

InFIG. 9B, since the feed-only openers10aand10bare vacant, the transport mechanism30transports FOUP1from the incoming rack21to the opener10aused with priority. After FOUP1is transported, the indexer mechanism7takes wafers W out of FOUP1set to the opener10a. After FOUP1is transported, FOUP2is transported by the external transport device40to the incoming rack21vacated by FOUP1.

InFIG. 9C, FOUP1is in the process of feeding wafers W. Since the feed-only opener10bis vacant, FOUP2is transported from the incoming rack21to the opener10b. After FOUP2is transported, and as soon as the feeding of wafers W from FOUP1is completed, wafers W are fed from FOUP2. After FOUP2is transported, FOUP3is transported by the external transport device40to the incoming rack21vacated by FOUP2.

InFIG. 9D, the feeding of wafers W from FOUP1has been completed, and empty FOUP1is transported to the collect-only opener10cor10d. Since both collect-only openers10cand10dare vacant at this time, empty FOUP1is transported from the feed-only opener10ato the collect-only opener10cused with priority. After empty FOUP1is transported, FOUP1stands by on the opener10cuntil treatment of the wafers W is completed. FOUP2is in the process of feeding wafers W. After FOUP1is transported, FOUP3is transported to the feed-only opener10avacated by FOUP1. After FOUP3is transported, FOUP4is transported by the external transport device40to the incoming rack21vacated by FOUP3.

InFIG. 9E, FOUP1is on standby. The feeding of wafers W from FOUP2has been completed, and FOUP2is transported to the collect-only opener10cor10d. Since the collect-only opener10dis vacant at this time, empty FOUP2is transported from the feed-only opener10bto the collect-only opener10d. After FOUP2is transported, FOUP2stands by on the collect-only opener10duntil treatment of the wafers W is completed. FOUP3is in the process of feeding wafers W. After FOUP2is transported, FOUP4is transported from the incoming rack21to the feed-only opener10bvacated by FOUP2. After FOUP4is transported, FOUP5is transported by the external transport device40to the incoming rack21vacated by FOUP4.

InFIG. 9F, FOUPs1and2are on standby. The feeding of wafers W from FOUP3on the feed-only opener10ahas been completed, and empty FOUP3is transported from the opener10a. FOUPs1and2still occupy (remain on standby) the collect-only openers10cand10d, and so a determination is made next whether the mid-treatment storage racks BF1and BF2are vacant. Since the mid-treatment storage racks BF1and BF2are both vacant, empty FOUP3is transported from the feed-only opener10ato the mid-treatment storage rack BF1used with priority. After FOUP3is transported, FOUP3stands by on the mid-treatment storage rack BF1until the collect-only opener10cor10dbecomes vacant. FOUP4is in the process of feeding wafers W. After FOUP3is transported, FOUP5is transported from the incoming rack21to the feed-only opener10avacated by FOUP3. After FOUP5is transported, FOUP6is transported by the external transport device40to the incoming rack21vacated by FOUP5.

InFIG. 9G, FOUP1successively receives treated wafers W for collection. FOUPs2and3are on standby. The feeding of wafers W from FOUP4on the feed-only opener10bhas been completed, and empty FOUP4is transported from the opener10b. Since neither of the collect-only openers10cand10dis vacant at this time, empty FOUP4is transported to the vacant mid-treatment storage rack BF2. After FOUP4is transported, FOUP4stands by on the mid-treatment storage rack BF2until the collect-only opener10cor10dbecomes vacant, and until after the preceding FOUP3leaves the mid-treatment storage rack BF1. FOUP5is in the process of feeding wafers W. After FOUP4is transported, FOUP6is transported from the incoming rack21to the feed-only opener10bvacated by FOUP4. After FOUP6is transported, FOUP7is transported by the external transport device40to the incoming rack21vacated by FOUP6.

InFIG. 9H, FOUP1having finished collecting wafers W is transported to the outgoing rack22which is vacant. FOUP2is collecting treated wafers W successively. After FOUP1is transported, FOUP3is transported from the mid-treatment storage rack BF1to the collect-only opener10cvacated by FOUP1. FOUP4is on standby. After FOUP3is transported, empty FOUP5having finished feeding wafers W is transported to the mid-treatment storage rack BF1vacated by FOUP3. After FOUP5is transported, FOUP5stands by on the mid-treatment storage rack BF1until the collect-only opener10cor10dbecomes vacant, and until after the preceding FOUP4leaves the mid-treatment storage rack BF2. FOUP6is in the process of feeding wafers W. After FOUP5is transported, FOUP7is transported from the incoming rack21to the feed-only opener10avacated by FOUP5. After FOUP7is transported, FOUP8is transported by the external transport device40to the incoming rack21vacated by FOUP7.

InFIG. 9I, FOUP1is transported by the external transport device40to the next apparatus, for example. After FOUP1is transported, FOUP2is transported from the collect-only opener10dto the outgoing rack22vacated by FOUP1. After FOUP2is transported, FOUP4is transported from the mid-treatment storage rack BF2to the collect-only opener10dvacated by FOUP2. FOUP5is on standby. After FOUP4is transported, empty FOUP6having finished feeding wafers W is transported to the mid-treatment storage rack BF2vacated by FOUP4. After FOUP6is transported, FOUP6stands by on the mid-treatment storage rack BF2until the collect-only opener10cor10dbecomes vacant, and until after the preceding FOUP5leaves the mid-treatment storage rack BF1. FOUP7is in the process of feeding wafers W. After FOUP6is transported, FOUP8is transported from the incoming rack21to the feed-only opener10bvacated by FOUP6. After FOUP8is transported, FOUP9is transported by the external transport device40to the incoming rack21vacated by FOUP8.

Subsequently, the operation described with reference toFIGS. 9H and 9Iis repeated for transporting FOUPs consecutively with the same timing.

InFIG. 9J, it is assumed that trouble has occurred with the external transport device40, whereby the external transport device40becomes unable to transport a FOUP placed on the outgoing rack22. FOUP2stands by on the outgoing rack22. Since the outgoing rack22is occupied, FOUP3having finished collecting wafers W is transported to the post-treatment storage rack BFA which is vacant. FOUP4is collecting treated wafers W successively. After FOUP3is transported, FOUP5is transported from the mid-treatment storage rack BF1to the collect-only opener10cvacated by FOUP3. FOUP6is on standby. After FOUP5is transported, empty FOUP7having finished feeding wafers W is transported to the mid-treatment storage rack BF1vacated by FOUP5. After FOUP7is transported, FOUP7stands by on the mid-treatment storage rack BF1until the collect-only opener10cor10dbecomes vacant, and until after the preceding FOUP6leaves the mid-treatment storage rack BF2. FOUP8is in the process of feeding wafers W. After FOUP7is transported, FOUP9is transported from the incoming rack21to the feed-only opener10avacated by FOUP7. After FOUP9is transported, FOUP10is transported by the external transport device40to the incoming rack21vacated by FOUP9.

Thus, with the post-treatment storage rack BFA provided, even when trouble occurs with the external transport device40, whereby the external transport device40becomes unable to transport FOUP F placed on the outgoing rack22, the apparatus can continue its operation without interrupting treatment.

When the current timing of transport is maintained thereafter, the FOUPs are transported while the post-treatment storage rack BFA remains blocked. However, the state of not using the post-treatment storage rack BFA may be reinstated by advancing the timing of transporting FOUPs F from the outgoing rack22to the external transport device40.

InFIG. 9K, it is assumed that, following the state shown inFIG. 9J, FOUP2on the outgoing rack22cannot be transported because of the trouble with the external transport device40. Since the outgoing rack22is occupied, FOUP3remains on standby on the post-treatment storage rack BFA. Since neither of the outgoing rack22and post-treatment storage rack BFA is vacant, FOUP4having finished collecting wafers W stands by on the collect-only opener10d. FOUP5is in the process of collecting treated wafers W successively. FOUPs6and7are on standby. Since the collect-only openers10cand10dand the mid-treatment storage racks BF1and BF2are all occupied, empty FOUP8having finished feeding wafers W stands by on the feed-only opener10b. FOUP9is in the process of feeding wafers W. Since the feed-only openers10aand10bare occupied, FOUP10is transported from the incoming rack21to the pre-treatment storage rack BFB which is vacant. After FOUP10is transported, FOUP11is transported by the external transport device40to the incoming rack21vacated by FOUP10.

Thus, with the pre-treatment storage rack BFB provided, even when FOUPs cannot be transported to the feed-only opener10aor10b, FOUP F on the incoming rack21can be transported to the pre-treatment storage rack BFB. Consequently, even when the external transport device40is transporting a FOUP F halfway from an upstream apparatus, FOUP F can be transported to the incoming rack21without interrupting the transport.

As described above, in the stocker apparatus2with the feed-only openers10aand10b, collect-only openers10cand10d, and racks20for receiving FOUPs F, as shown inFIG. 4, individual FOUPs F are successively transported, with determinations made whether the destination openers10or racks20are vacant, based on the flow chart shown inFIG. 8. Based on this flow chart, a plurality of FOUPs F act in parallel as shown inFIGS. 9A through 9K. This increases the efficiency of transporting FOUPs F as describe hereinafter, thereby allowing the substrates to be fed and collected efficiently.

<Advantages of the Stocker Apparatus2according to the Embodiment>

The advantages of the stocker apparatus2according to the embodiment will be described as compared with the conventional apparatus not having the stocker apparatus2.

FIG. 10is a working diagram showing operation of the conventional apparatus having four openers101a-101d(hereinafter called the first conventional apparatus).FIG. 11is a working diagram showing operation of the conventional apparatus having six openers101a-101f(hereinafter called the second conventional apparatus).FIG. 12is a working diagram showing operation of the stocker apparatus2having four openers10a-10dand two mid-treatment storage racks BF1and BF2according to the embodiment.

Here, description will be made of operations taking place when each of the substrate treating apparatus according to the embodiment and the first and second conventional apparatus handles 12 FOUPs F (each FOUP storing 25 wafers W). As will be clear from the following description, the apparatus with the stocker apparatus2having four openers10a-10dand two mid-treatment storage racks BF1and BF2according to the embodiment achieves the same FOUP transporting efficiency as the second conventional apparatus having six openers101a-101f. FOUP transporting operation will be described hereinafter in order of the first conventional apparatus, second conventional apparatus, and apparatus according to the embodiment.

In the working diagrams shownFIGS. 10 through 12, the vertical axis represents the openers10and101, or the mid-treatment storage racks BF, while the horizontal represents time steps. The spacing between the time steps is irrelevant to real time.

{Operation of the First Conventional Apparatus Having Four Openers101a-101d}

Reference is made toFIG. 10. As used inFIG. 10, sign “ldn” means operation for placing FOUPs F on the openers101. Sign “snd” means operation for feeding wafers W from FOUPs F. Sign “rtn” means operation for collecting wafers W into FOUPs F. Sign “ulf” means operation for unloading FOUPs F from the apparatus. Sign “wt” means a standby state (idle state). Numeral “1” in “ldn1” indicates a FOUP F transported, and in this case indicates the first FOUP F. For example, an operation for placing the 12th FOUP F on opener101is expressed as “ldn12”. In describing the operation, 12 FOUPs are processed by way of example.

First, steps of loading FOUPs F into the substrate treating apparatus, feeding and collecting wafers W and unloading FOUPs F from the apparatus will be described by taking FOUP1on the opener101afor example.

In step2, FOUP1is placed on the opener101aby the external transport device40(ldn1). Next, in steps3and4, the indexer mechanism7feeds wafers W from FOUP1to the substrate treating apparatus main body1(snd). The wafers W fed successively receive a predetermined treatment in each treating unit of the substrate treating apparatus. In steps5-9, FOUP1is kept on standby (wt), with no transport action taking place, since the wafers W are being treated successively. During this period, empty FOUP1with all the wafers W fed out stands by in the same position. In steps10and11, the indexer mechanism7successively collects treated wafers W back into FOUP1(rtn). In step12, FOUP1having collected the treated wafers W is transported to the next apparatus by the external transport device40(ulf1).

The above is the treating process for one FOUP F.

The processing of FOUPs F is carried out using the opener101a, which is followed by the opener101b, opener101cand opener101din the stated order. After the opener101d, substrate treatment is carried out again for FOUP F on the opener101a.

The operation for feeding wafers W from FOUPs F is carried out in such a way that, for example, after wafers W are fed from FOUP1placed on the opener101a(step4), and as soon as necessary preparations are completed, wafers W are fed from FOUP2placed on the opener101b(step5).

Similarly, the operation for collecting wafers W into FOUPs F is carried out in such a way that, for example, after wafers W are collected into FOUP1placed on the opener101a(step11), and as soon as necessary preparations are completed, wafers W are collected into FOUP2placed on the opener101b(step12).

According to the working diagram shown inFIG. 10, the processing for the 12 FOUPs F is completed when the last FOUP F is taken out by the external transport device40in step40.

{Operation of the Second Conventional Apparatus Having Six Openers101a-101f}

Reference is made toFIG. 11. The signs and numerals used inFIG. 11are the same in meaning as inFIG. 10. The processing of one FOUP F is as described above.

The processing of FOUPs F is carried out in the order of openers101a,101b,101c,101d,101eand101f. After the opener101f, processing is carried out again for FOUP F on the opener101a.

The operation for feeding wafers W is carried out as described above. That is, after wafers W have been fed from one FOUP F, and as soon as preparations are completed for FOUP F placed on the opener101next in order, wafers W are fed from that FOUP F.

The operation for collecting wafers W is carried out also as described above. That is, after wafers W have been collected into one FOUP F, and as soon as preparations are completed for FOUP F placed on the opener101next in order, wafers W are collected into that FOUP F.

According to the working diagram shown inFIG. 11, the processing for the 12 FOUPs F is completed when the last FOUP F is taken out by the external transport device40in step34.

The first conventional apparatus having four openers101a-101dshown inFIG. 10completes the processing for the 12 FOUPs in step40. On the other hand, the second conventional apparatus having six openers101a-101fshown inFIG. 11completes the processing in step34. Thus, the second conventional apparatus has a higher efficiency of transporting the FOUPs than the first conventional apparatus. This is because, as shown inFIG. 11, wafers W are fed from the FOUPs F placed on the openers101a-101fsuch that, in steps14and15, the indexer mechanism7, after having fed all the wafers W from the FOUP F placed on the opener101f, continues to feed wafers W from the FOUP F on the opener101a. Similarly, the collection of wafers W is carried out continuously. That is, the second conventional apparatus carries out the feeding and collection of wafers W continuously.

With the first conventional apparatus shown inFIG. 10, on the other hand, in steps10-14, when the feeding of wafers W from FOUP4placed on the opener101dis completed, FOUP1on the next opener101ais still in the midst of successively collecting treated wafers W (step11). That is, after treated wafers W are collected in FOUP1on the opener101a, FOUP1is transported to the next apparatus by the external transport device40, then FOUP5storing wafers W to be treated is transported, but these wafers W can be fed only after preparations are completed. The situation is the same in steps21-25also.

With the first conventional apparatus shown inFIG. 10, in steps17-21, when the collection of wafers W in FOUP4placed on the opener101dis completed, the next opener101ais in the state of the wafers W fed therefrom still being treated (step18). That is, the operation for collecting wafers W can be carried out only after completion of the treatment of the wafers W fed from FOUP F on the opener101a. The situation is the same in steps28-32also.

That is, the first conventional apparatus having four openers cannot carry out the feeding and collection of wafers W continuously, and has a lower efficiency of transporting the FOUPs than the second conventional apparatus. This results in a longer time taken before completion of the treatment.

{Operation of the Substrate Treating Apparatus with Stocker Apparatus2in This Embodiment}

FIG. 12is a working diagram of the substrate treating apparatus with the stocker apparatus2(four openers10a-10dand two mid-treatment storage racks BF1and BF2) in this embodiment. The openers10aand10bare used exclusively for feeding wafers W to be treated, and the openers10cand10dexclusively for collecting treated wafers W.

The signs and numerals used inFIG. 12are the same in meaning as inFIG. 10. The meanings of additional signs used inFIG. 12are as follows. Sign “uld” means an operation for transporting FOUP F having fed wafers W from one of the feed-only openers10to a different location. Sign “ldu” means an operation for transporting empty FOUP F from a different location to one of the collect-only openers10. Sign “push” means an operation for transporting empty FOUP F from one of the feed-only openers10to one of the mid-treatment storage racks BF. Sign “pop” means an operation for transporting empty FOUP F from one of the mid-treatment storage racks BF to one of the collect-only openers10.

The processing of one FOUP F not using the mid-treatment storage rack BF1or BF2, and that using the mid-treatment storage rack BF1or BF2, will be described in order.

First, the processing of one FOUP F not using the mid-treatment storage rack BF1or BF2will be described taking “FOUP1” for example.

In step2, FOUP1placed on the incoming rack21by the external transport device40is transported to the opener10a(ldn1). In steps3and4, the indexer mechanism7feeds wafers W from FOUP1(snd). The wafers W fed successively receive a predetermined treatment in each treating unit of the substrate treating apparatus. In step5, the transport mechanism30transports FOUP1made empty of wafers W to a different location. The collect-only openers10cand10dare both vacant at this time, and empty FOUP1is transported to the opener10c(uld1for opener10a, and ldu1for opener10c). In steps6-9, FOUP1is kept on standby (wt), with no transport action taking place, since the wafers W are being treated. In steps10and11, the indexer mechanism7successively collects treated wafers W into FOUP1transported to the opener10c(rtn). In step12, the transport mechanism30transports FOUP1having collected the treated wafers W from the opener10cto the outgoing rack22. FOUP1transported to the outgoing rack22is transported to the next apparatus by the external transport device40(ulf1for opener10c).

Next, the processing of one FOUP F using the mid-treatment storage rack BF1or BF2will be described taking “FOUP5” for example.

In step10, FOUP5placed on the incoming rack21by the external transport device40is transported to the opener10a(ldn5). In steps11and12, the indexer mechanism7feeds wafers W from FOUP5(snd). The wafers W fed successively receive the predetermined treatment in each treating unit of the substrate treating apparatus. In step13, the transport mechanism30transports FOUP5made empty of wafers W to a different location. At this time, the collect-only opener10creceives FOUP3transported from the mid-treatment storage rack BF1(pop3, Idu3), and the collect-only opener10dis occupied by FOUP2which is collecting treated wafers W successively (rtn). That is, neither of the collect-only openers10cand10dis vacant. Thus, FOUP5is transported to the mid-treatment storage rack BF1vacated by FOUP3having been transported to the opener10c(uld5for opener10a, and pushy for mid-treatment storage rack BF1). In steps14-16, the mid-treatment storage rack BF1is in a standby state with no transport operation taking place (wt). In step17, FOUP3is transported from the opener10cto the outgoing rack22(ulf3), leaving the opener10cvacant. At this time, FOUP5has been deposited before FOUP6present on the mid-treatment storage rack BF2. FOUP5therefore is transported with priority (pop5for mid-treatment storage rack BF1, and Idu5for opener10c). Incidentally, FOUP7is transported to the mid-treatment storage rack BF1vacated by FOUP5(uld7, push7). In steps18and19, the indexer mechanism7successively collects treated wafers W into FOUP5on the opener10c(rtn). In step20, FOUP5having collected treated wafers W is transported from the opener10cto the outgoing rack22. FOUP5transported to the outgoing rack22is transported to the next apparatus by the external transport device40(step20, ulf5for opener10c).

The feeding of wafers W is carried out alternately in the order of opener10a, opener10b,10a,10b,10a, . . . . The collection of wafers W is carried out alternately in the order of opener10c, opener10d,10c,10d,10c, . . . .

According to the working diagram shown inFIG. 12, the processing for the 12 FOUPs F is completed when the last FOUP F is taken out by the external transport device40in step34. That is, the apparatus in this embodiment completes the operation with the same number of steps as the foregoing second conventional apparatus having six openers101shown inFIG. 11. This is because both apparatus feed wafers W continuously.

The substrate treating apparatus with the stocker apparatus2in this embodiment and the second conventional apparatus having six openers101a-101f, as shown in step12inFIG. 12andFIG. 11, for example, carry out a step of feeding wafer W to be treated from FOUP F, a step of collecting treated wafers W in FOUP F, a step of putting FOUP F made empty of wafers W on standby, a step of placing FOUP F storing wafers W to be treated on the opener10or101, and a step of causing FOUP F for which the substrate treatment is completed to be transported to the next apparatus. That is, the two apparatus carry out the same operation although their constructions are different.

That is, the substrate treating apparatus with the stocker apparatus2in this embodiment realizes FOUP transporting efficiency comparable to that of the second conventional apparatus having six openers101, and can feed and collect wafers W continuously.

A comparison between the substrate treating apparatus with the stocker apparatus2in this embodiment and the second conventional apparatus shows that, while the apparatus in this embodiment has a width for accommodating four openers10juxtaposed, the second conventional apparatus has a width for accommodating six openers101. That is, the apparatus in this embodiment, compared with the second conventional apparatus having the same FOUP transporting efficiency, can reduce the size in the transverse (X-axis) direction of the apparatus, and can inhibit enlargement of the apparatus, that is an installation area at the time of installation in a factory or the like.

Where the conventional apparatus has the number of openers101increased to seven or eight, the apparatus in this embodiment can realize a similar effect easily by adding mid-treatment storage racks BF.

Modifications

This invention is not limited to the foregoing embodiment, but may be modified as set out below. Portions overlapping the foregoing embodiment will not be described.

The stocker apparatus2may include an interlock mechanism70for preventing interference taking place when the gripper42of the external transport device40and the gripper31of the transport mechanism30access the incoming rack21or outgoing rack22for transfer of FOUPs F at the same time. The term “transfer position” will be used hereinafter when not distinguished. The term “interlock mechanism70” will be used when interlock mechanisms70A-E described hereinafter are not distinguished. Description will be made in order starting with an interlock mechanism70A.

FIG. 13Ais a side view of a slide type interlock mechanism70A.FIG. 13Bis a front view of the slide type interlock mechanism70A.

The interlock mechanism70A includes a slide door71aslidable sideways to open and close, a slide door switch mechanism72afor opening and closing the slide door71a, and a sensor73afor detecting opening and closing of the slide door71a. The interlock mechanism70A is provided on a side of each of the incoming rack21and outgoing rack22to shut a passage through which the gripper31of the transport mechanism30accesses the incoming rack21or outgoing rack22for transfer of FOUP F.

The controller83of the stocker apparatus2drives the door switch mechanism72ato open and close the door71a, and receives a detection signal from the sensor73a. The controller83controls operation of the interlock mechanism70A as described hereinafter.

Usually, the slide door71ais open so that the transport mechanism30may access the transfer position. The controller83of the stocker apparatus2makes a determination based on the detection signal from the sensor73a, and transmits, to the central controller81of the factory through the main controller82of the substrate treating apparatus, information (hereinafter called “access propriety information” as appropriate) indicating whether the external transport device40may access the stocker apparatus2(access permitted) or not (access prohibited). In this case, information “access prohibited” is transmitted since the slide door71ais open so that the transport mechanism30can make access, and access of the external transport device40is prohibited. Based the access propriety information (access prohibited), the central controller81of the factory gives instructions (access prohibited) to the transport controller84of the external transport device40.

For example, when the external transport device40accesses the transfer position, as shown inFIG. 7, the transport controller84of the external transport device40transmits information requesting access to the transfer position of the stocker apparatus2(hereinafter called “access request information”) to the central controller81of the factory. The central controller81of the factory transmits this information to the controller83of the stocker apparatus2through the main controller82of the substrate treating apparatus. Upon receipt of the access request information, the controller83of the stocker apparatus2closes the slide door71ato prohibit access of the transport mechanism30to the transfer position. Based on the detection signal from the sensor73a, the controller83of the stocker apparatus2confirms that the slide door71ais closed, and transmits access propriety information (information of “access permitted”) to the central controller81of the factory through the main controller82of the substrate treating apparatus. Upon receipt of instructions from the central controller81of the factory, the transport controller84of the external transport device40accesses the transfer position.

After a transfer operation, the transport controller84of the external transport device40transmits, through the path noted above, information canceling the request for access to the transfer position of the stocker apparatus2(hereinafter called “access request cancel information”). Upon receipt of the access request cancel information, the controller83of the stocker apparatus2opens the slide door71a. Then, based on the signal from the sensor73a, the controller83transmits the access propriety information prohibiting access again.

When the controller83of the stocker apparatus2receives the access request information, the transport mechanism30may be engaged in an operation to transport a FOUP F between the transfer position and another position in response to instructions of the controller83of the stocker apparatus2. In such a case, the controller83waits until that operation is completed. Subsequently, the controller83of the stocker apparatus2closes the slide door71a.

The controller83of the stocker apparatus2may transmit the access propriety information, access request information or access request cancel information through the transporting controller84of the external transport device40to the central controller81of the factory which supervises production of the entire factory.

FIG. 14Ais a side view of a rotary type interlock mechanism70B.FIG. 14Bis a front view of the rotary type interlock mechanism70B.

The interlock mechanism70B includes a swing door71bwith a proximal end thereof rotatably supported to be swingable open and close, a swing door switch mechanism72bfor opening and closing the swing door71b, and a sensor73bfor detecting opening and closing of the swing door71b.

The controller83of the stocker apparatus2drives the door switch mechanism72bto open and close the swing door71b, and receives a detection signal from the sensor73b. Operation of the interlock mechanism70B is controlled as is operation of the interlock mechanism70A.

FIG. 15Ais a side view of an interlock mechanism70C.FIG. 15Bis a front view of the interlock mechanism70C.

The interlock mechanism70C includes a sensor73cdisposed laterally of a region of the transfer position for detecting the gripper31of the transport mechanism30entering from a side.

When the sensor73cdetects entry, that is when the gripper31of the transport mechanism30is present in the transfer position, the controller83of the stocker apparatus2prohibits access of the external transport device40to the transfer position of the stocker apparatus2. On the other hand, when the sensor73does not detect entry, that is when the gripper31of the transport mechanism30is absent from the transfer position, the controller83of the stocker apparatus2permits access of the external transport device40to the transfer position of the stocker apparatus2.

For example, when the external transport device40accesses the transfer position, as shown inFIG. 7, the transport controller84of the external transport device40transmits access request information to the central controller81of the factory. The central controller81of the factory transmits this information to the controller83of the stocker apparatus2through the main controller82of the substrate treating apparatus. Upon receipt of the access request information, the controller83of the stocker apparatus2transmits access propriety information determined based on the detection signal from the sensor73c, to the central controller81of the factory through the main controller82of the substrate treating apparatus. The central controller81of the factory gives instructions based on the access propriety information to the transport controller84of the external transport device40. On these instructions the external transport device40accesses the transfer position.

FIG. 16Ais a side view of an interlock mechanism70D.FIG. 16Bis a front view of the interlock mechanism70D.

The interlock mechanism70D includes a sensor73ddisposed above the transfer position for detecting the gripper41of the external transport device40entering from above.

When the sensor73ddetects entry, that is when the gripper41of the external transport device40is present in the transfer position, the controller83of the stocker apparatus2prohibits access of the gripper31of the transport mechanism30to the transfer position.

Communication of information is carried out when the external transport device40accesses the transfer position, as described in relation to the interlock mechanism70C.

FIG. 17is a view showing an interlock mechanism70E.

The interlock mechanism70E includes a sensor73efor monitoring coordinates, which is attached to the second moving mechanisms35for moving the transport mechanism30in vertical (Z-axis) directions.

This sensor73eis arranged to detect the first moving mechanism34of the transport mechanism30at a height corresponding to the transfer position. When the sensor73edetects it, that is when the position in the vertical (Z-axis) direction of the first moving mechanism34of the transport mechanism30is at a height for accessing the transfer position, the controller83of the stocker apparatus2prohibits the external transport device40from accessing the transfer position of the stocker apparatus2. When the sensor73emakes no detection, that is when the position in the vertical (Z-axis) direction of the first moving mechanism34of the transport mechanism30is not at the height for accessing the transfer position, the controller83of the stocker apparatus2permits the external transport device40to access the transfer position of the stocker apparatus2.

Communication of information is carried out when the external transport device40accesses the transfer position, as described in relation to the interlock mechanism70C.

(2) Stocker Apparatus2Having Transport Mechanism30Which Transports FOUPs F as Supported in Position Directly above Horizontal Transport Path (First Moving Mechanism34) of Transport Mechanism30:

In the foregoing embodiment, as shown inFIGS. 3 through 5, the stocker apparatus2has the space SP1between the transport mechanism30and racks20for allowing passage of FOUPs F, whereby the transport mechanism30can freely move FOUPs F in the directions of XZ plane. However, the provision of space SP1results in an increased length of the stocker apparatus2(the length in the direction of Y-axis). Compared with this, as shown inFIG. 18, the transport mechanism30may be constructed rotatable after drawing FOUP F close thereto, to support it in a position directly above the first moving mechanism34of the transport mechanism30, and then to move on the XZ plane to transport the FOUP F. This construction can dispense with the above space SP1. Consequently, the size in the longitudinal (Y-axis) direction of the stocker apparatus2(substrate treating apparatus) can be reduced to inhibit enlargement of the apparatus.

In the foregoing embodiment, the stocker apparatus2transfers FOUPs F to and from the external transport device40through the incoming rack21or outgoing rack22. However, as shown inFIG. 19, a load port12may be provided in a position opposed to the openers10across the transport mechanism30for receiving FOUPs F, and through this load port12FOUPs F may be transferred to and from the external transport device40or people (workers).

FIG. 19is a side view in vertical section of the stocker apparatus2.FIG. 20Ais a section taken on line G-G ofFIG. 19.FIG. 20Bis a front view showing a portion including the load port12.FIG. 21is a section taken on line H-H ofFIG. 19.

As shown inFIG. 20B, the load port12for receiving FOUPs F has four load port trays13a-13dfor placing FOUPs F in predetermined positions. The term load port tray(s)13will be used hereinafter where the load port trays13a-13dare not distinguished. The load port trays13are used separately as incoming load port trays13aand13bwhere FOUPs F storing wafers W to be treated are placed, and outgoing load port trays13cand13dwhere FOUPs F storing treated wafers W are placed.

In the above description, the load port12has four load port trays13. However, the number of load port trays13may be two or three.

In the above description, the four load port trays13of the load port12are used separately as two incoming load port trays13and two outgoing load port trays13. However, these trays13may be used as three incoming load port trays13and one outgoing load port tray13. They may be used as one incoming load port tray13and three outgoing load port trays13.

In this modification, the stocker apparatus2newly includes the load port12. Therefore, the rack20used as incoming rack21or outgoing rack22in the foregoing embodiment (FIG. 4) may be used, as appropriate, as pre-treatment storage rack BFB for keeping FOUP F storing wafers W to be treated, as mid-treatment storage rack BF for keeping empty FOUP F, or as post-treatment storage rack BFA for keeping FOUP F storing treated wafers W.

As shown inFIG. 21, the gripper31of the transport mechanism30grips FOUPs F placed on the load port trays13of the load port12, and transports them to the openers10or racks20. At this time, the transport mechanism30rotates after drawing each FOUP F close thereto, to support it in a position directly above the first moving mechanism34of the transport mechanism30, and then moves on the XZ plane to transport the FOUP.

(4) Stocker Apparatus2Having Racks50Each with an Open/Close Mechanism Which Opens and Closes Rack50Horizontally Right and Left:

In the foregoing embodiment, as shown inFIGS. 3through5, the stocker apparatus2allows the transport mechanism30to move FOUPs F through the space SP1between the transport mechanism30and racks20, whereby FOUPs F can move freely in the directions of XZ plane. However, as shown inFIGS. 22 through 24, the stocker apparatus2may have racks50each with a mechanism which opens and closes the rack50horizontally right and left. With this construction, each rack50holds FOUP F when closed, and allows the FOUP to be moved in the vertical (Z-axis) direction in that position when open. By providing a space SP2between the racks50and openers10a-10d, FOUPs F can be moved in the transverse (X-axis) direction, and thus are movable in the XZ plane.

FIG. 22is a side view in vertical section of the stocker apparatus2.FIG. 23is a section taken on line C-CFIG. 22.FIG. 24is a section taken on line D-D ofFIG. 22.

As shown inFIG. 25, each rack50includes a pair of rack bodies51aand51bfor supporting FOUP F, and a rack open/close mechanism52for opening and closing these rack bodies51aand51bhorizontally right and left. The rack open/close mechanism52has a pair of support rails53aand53binterconnecting and supporting the rack bodies51aand51b, and a pair of electric motors54aand54bconnected to the rack bodies51aand51bto carry out opening and closing operations.

The rack bodies51aand51bare freely movable on the support rails53aand53b, and are opened and closed by the electric motors54aand54b.

FIG. 26Ais a front view showing a closed state of the rack50horizontally openable and closable right and left shown inFIG. 25.FIG. 26Bis a front view showing an opened state of the rack50horizontally openable and closable right and left shown inFIG. 25. In the closed state, as shown inFIG. 26A, FOUP F shown in a two-dot chain line can be placed on the rack bodies51aand51bof the rack50. In the open state, as shown inFIG. 26B, FOUP F shown in a two-dot chain line can be moved up and down between the rack bodies51aand51bof the rack50.

The portions of the rack bodies51aand51bsupporting FOUP F are located outward of the portions connected to the support rails53aand53bof the rack bodies51aand51b. This reduces the size in the transverse direction.

Thus, the gripper31of the transport mechanism30, after gripping the FOUP F to be transported, can move the FOUP F in the vertical (Z-axis) direction in the position the FOUP F has been placed, by operating the rack open/close mechanism52to open the rack50. This construction can dispense with the space SP1(FIG. 3) for allowing passage of FOUPs F in the foregoing embodiment. Consequently, the size in the longitudinal (Y-axis) direction can be reduced. Enlargement of the apparatus can be inhibited.

(5) Stocker Apparatus2having Space SP3abetween Two Racks20Juxtaposed in the Transverse Direction for Allowing FOUPs F to Move in the Vertical (Z-Axis) Direction:

A modified embodiment will be described, which can dispense with the FOUP moving space SP1in the embodiment shown inFIG. 3, to shorten the apparatus in the longitudinal (Y-axis) direction

FIG. 27is a sectional front view of the stocker apparatus2.FIG. 28is a cross section of the transport mechanism area of the stocker apparatus2(a side view in vertical section of the stocker apparatus2is the same as that ofFIG. 22).

As shown inFIG. 27, the stocker apparatus2has a space SP3abetween two racks20juxtaposed in the transverse direction for allowing FOUPs F to move in the vertical (Z-axis) direction. The stocker apparatus2has also a space SP3bbetween the racks20and openers10for allowing FOUPs F to move in the transverse (X-axis) direction. When moving FOUPs F, the transport mechanism30moves, for example, FOUP F placed on the incoming rack21horizontally and slightly rightward inFIG. 27, and places the FOUP F in the space SP3a. Then, the FOUP F is lowered within the space SP3ainto the space SP3b. Further, the FOUP F is moved within the space SP3bleftward inFIG. 27, and is placed on the opener10a.

According to this construction, even where the racks20are not provided with the mechanisms for opening and closing horizontally right and left as in the foregoing modification (4), the size in the longitudinal (Y-axis) direction can be reduced and enlargement of the apparatus can be inhibited.

As shown inFIG. 28, this construction requires a width corresponding to five openers10, thereby increasing the size in the transverse (X-axis) direction. However, the stocker apparatus2may have a fifth opener10as shown in two-dot chain lines inFIG. 27. Consequently, the apparatus may be used in the manner of operation described in the embodiment of this invention, or five openers10may be adopted as in the conventional method. In this case, the racks20other than the incoming rack21and outgoing rack22may be used as pre-treatment storage racks BFB and post-treatment storage racks BFA.

(6) Arrangement of Pre-Treatment Storage Rack BFB, Mid-Treatment Storage Racks BF and Post-Treatment Storage Rack BFA of Stocker Apparatus2:

In the foregoing embodiment, the stocker apparatus2has the pre-treatment storage rack BFB, mid-treatment storage racks BF and post-treatment storage rack BFA whose specific positional relationships are not particularly defined. However, the pre-treatment storage rack BFB may be disposed closer to the incoming rack21than the other racks such as the mid-treatment storage racks BF. Similarly, the post-treatment storage rack BFA may be disposed closer to the outgoing rack22than the other racks such as the mid-treatment storage racks BF. The mid-treatment storage racks BF may be arranged closer to positions between the feed-only openers10and collect-only openers10than the other racks BFB and BFA. Such arrangement will realize FOUP transport with improved efficiency.

(7) Numbers of Pre-Treatment Storage Racks BFB, Mid-Treatment Storage Racks BF1and BF2and Post-Treatment Storage Racks BFA of the Stocker Apparatus2:

In the foregoing embodiment, the stocker apparatus2has one pre-treatment storage rack BFB, two mid-treatment storage racks BF and one post-treatment storage rack BFA. However, this construction is not limitative. For example, the stocker apparatus2may have two pre-treatment storage racks BFB, three mid-treatment storage racks BF and two post-treatment storage racks BFA. The stocker apparatus2may have three pre-treatment storage racks BFB, two mid-treatment storage racks BF and four post-treatment storage racks BFA.

(8) The Feed-Only Openers and Collect-Only Openers of Stocker Apparatus2:

In the foregoing embodiment, the four openers10a-10dhave different roles to play, such that the two left openers10aand10bare used only for feeding wafers W, and the two right openers10cand10donly for collecting wafers W. However, this construction is not limitative. The two right openers10cand10dmay be used only for feeding wafers W, and the two left openers10aand10bonly for collecting wafers W.