PROPORTIONAL FLUID FLOW VALVE AND METHODS OF OPERATING THEREOF

Certain embodiments of the present disclosure relate to a fluid flow valve. The valve includes a housing configured to receive a flow of fluid. The valve further includes a diaphragm to actuate between a closed position and a plurality of open positions. The valve further includes a first valve portion configured to flow a first amount of fluid responsive to the diaphragm actuating to one or more first open positions of the plurality of open positions. The valve further includes a second valve portion in parallel with the first valve portion and configured to flow a second amount of fluid responsive to the diaphragm actuating to one or more second open positions of the plurality of open positions.

TECHNICAL FIELD

Embodiments of the present disclosure relate, in general, to a proportional valve for controlling a flow of fluid.

BACKGROUND

Various manufacturing systems (e.g., for semiconductor applications) may include fluid control valves control the amount of fluid flowed e.g., to a process chamber. In some manufacturing systems, process gases (e.g., gases used during semiconductor fabrication processes) and/or cleaning gases (e.g., gases used to clean a manufactured device and/or a chamber used in manufacturing an electronic device) may have precise delivery targets including high mass flow rates as well as the ability to precisely control low flow rates.

SUMMARY

Certain embodiments of the present disclosure relate to a fluid flow valve including a housing configured to receive a flow of fluid. The valve further includes a diaphragm configured to actuate between a closed position and a plurality of open positions. The valve further includes a first valve portion configured to flow a first amount of fluid responsive to the diaphragm actuating to one or more first open positions of the plurality of open positions. The valve further includes a second valve portion in parallel with the first valve portion and configured to flow a second amount of fluid responsive to the diaphragm actuating to one or more second open positions of the plurality of open positions.

In another aspect of the disclosure, a fluid flow system includes a valve and a processing device. The valve includes a housing configured to receive a flow of fluid. The valve further includes a diaphragm configured to actuate between a closed position and a plurality of open positions. The valve further includes a first valve portion and a second valve portion in parallel with the first valve portion. The processing device is configured to cause the first valve portion to flow a first amount of fluid by causing the diaphragm to actuate to one or more first open positions of the plurality of open positions. The processing device is further configured to cause the second valve portion to flow a second amount of fluid by causing the diaphragm to actuate to one or more second open positions of the plurality of open positions.

In another aspect of the disclosure, a method includes receiving target flow data associated with a flow of fluid through a valve having a first valve portion and a second valve portion in parallel with the first valve portion. The method further includes causing a diaphragm to actuate to one or more first open positions to flow a first amount of fluid through the first valve portion based at least in part on the target flow data. The method further includes causing the diaphragm to actuate to one or more second open positions to flow a greater second amount of fluid through at least the second valve portion based at least in part on the target flow data.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments described herein relate to a fluid flow valve (e.g., a gas flow valve), a fluid flow system incorporating the same, and a method of controlling the fluid flow valve. Generally, it is advantageous to proportionally control the flow of gas to a system such as a substrate manufacturing system. Conventional gas distribution systems (e.g., fluid distribution systems) use mass flow controllers (MFCs) to regulate the flow of gas to a target flow rate. MFCs are typically complicated and add significant cost to the system along with increased maintenance. Additionally, MFCs typically suffer from slow response times which can adversely affect substrate processing. For example, MFCs can often have a response time greater than 700 milliseconds. The long response times of typical MFCs are not suitable for short duration process recipe operations which use quick adjustments of gas flow. Further, MFCs often include moving parts in the wetted flow path. Movement of these parts in the wetted flow path can lead to the generation of particles that can be carried into a process chamber and adversely affect the substrate process and/or become deposited on a processed substrate, leading to imperfections and/or scrapping of the processed substrate. Moreover, MFCs often have a limited flow range along with poor control at low flow rates.

Aspects and implementations of the instant disclosure address the above-described and/or other shortcomings of conventional fluid flow valves and systems by providing a fluid flow valve having two parallel valve portions to proportionally control the flow of fluid through the valve. In some embodiments, the fluid valve described herein is able to control a flow of fluid (e.g., for semiconductor processing) at very high response times (e.g., less than 20 milliseconds) using a fast actuator such as a piezo-based actuator (e.g., a piezoelectric-based actuator) or a solenoid-based actuator. The fluid valve described herein may have the capability to control a wide flow range with fine control throughout the flow range. In some embodiments, the fluid flow valve described herein includes direct feedback on a diaphragm displacement (e.g., via a strain gauge bonded to the diaphragm) to ensure accurate, repeatable, and/or reproducible fluid flow delivery.

In some embodiments, a fluid flow valve includes a housing to receive a flow of fluid (e.g., a flow of gas from a gas source, etc.). The housing may have one or more internal passages to flow the fluid along one or more fluid flow paths within the housing. The fluid may be a process gas such as nitrogen, argon, etc. The fluid may be a corrosive gas, for example, a gas used in substrate etching operations, etc. In some embodiments, the housing includes a base portion that is to couple to a fluid flow assembly (e.g., a gas flow assembly, a gas stick assembly, etc.).100211In some embodiments, a fluid flow valve includes a first valve portion and a second valve portion in parallel with the first valve portion. The first and second valve portions may be opened or closed by the actuation of a diaphragm. In some embodiments, a diaphragm disposed within the housing can be actuated between a closed position and multiple open positions. In some embodiments, a first portion of the diaphragm's range of movement actuates the first valve portion and not the second valve portion, while a second portion of the diaphragm's range of movement actuates both the first valve portion and the second valve portion. In some embodiments, the diaphragm can be actuated to open the first valve portion without opening the second valve portion. In some embodiments, after the diaphragm is actuated beyond a threshold position, the second valve portion opens.

In some embodiments, the first valve portion is configured to flow a first amount of fluid responsive to the diaphragm actuating to an open position up to the threshold position. In some embodiments, the second valve portion is configured to flow a second amount of fluid responsive to the diaphragm actuating to an open position beyond the threshold position. In some embodiments, fluid flow through the second valve portion is to combine with fluid flow through the first valve portion. In some embodiments, the first valve portion and the second valve portion are enabled by a dual poppet valve design. An inner poppet (e.g., an inner poppet valve, etc.) corresponding to the first valve portion may be opened by the diaphragm in the first part of the diaphragm's range of motion, and one or more outer poppets (e.g., one or more outer poppet valves, etc.) corresponding to the second valve portion may be opened by the diaphragm in the second part of the diaphragm's range of motion. In some embodiments, a poppet (e.g., a poppet valve) includes a plug that seals against a sealing surface forming a hole. Fluid is allowed to flow past the plug when the plug is unseated from the sealing surface. In some embodiments, the flow of fluid through the first valve portion is relatively small compared to the flow of fluid through the second valve portion. This way, a “soft start” of fluid flow and/or precise metering of small fluid flows can be accomplished. By combining a large flow of fluid through the second valve portion with the relatively smaller flow of fluid through the first valve portion, fine control of the overall combined fluid flow can be accomplished over a wide range of flowrates.

In some embodiments, the diaphragm is actuated by a fast actuator such as a piezoelectric-based actuator or a solenoid-based actuator. In some embodiments, the fluid flow valve has a response time less than 20 milliseconds. The diaphragm may be actuated by a stacked piezoelectric actuator, a voice coil actuator, or a bending piezoelectric actuator. In some embodiments, a strain gauge is coupled to the diaphragm so that feedback loop control can be established. For example, a controller can control the actuator to actuate the diaphragm based on the position of the diaphragm sensed by the strain gauge. In some embodiments, the fluid flow valve is controlled (e.g., by the controller) based on target flowrate data and/or target pressure data, sensed flowrate data, sensed pressure data, and/or position data associated with the first and/or second valve portions.

Embodiments of the present disclosure provide advantages over conventional systems, valves, and MFCs described above. Particularly, some embodiments described herein provide a fluid flow valve that can control the flowrate of a fluid with fine control over a wide range of flowrates. This is accomplished by including the first valve portion to flow a small amount of fluid and the second valve portion to flow a relatively larger amount of fluid. Further, the fluid valve described herein provides mass flow control of a fluid and can also provide pressure control of the fluid. Moreover, the fluid valve described herein provides a quicker response time than conventional MFCs for adjusting fluid flowrates, allowing for more precise and quicker control for process operations. Additionally, a strain gauge-based position feedback enables improved flow control accuracy. Furthermore, the fluid valve described herein includes no moving parts in the wetted flow path, leading to reduced particle generation which can improve substrate processing system throughput.

FIG.1depicts a system100that includes a processing chamber101, a gas source160, and a flow control apparatus (e.g., gas stick assembly200) in accordance with embodiments of the present disclosure. The processing chamber101may be used for processes in which a corrosive plasma environment is provided. For example, the processing chamber101may be a chamber for a plasma etcher or plasma etch reactor, a plasma cleaner, and so forth. In alternative embodiments, other processing chambers may be used, which may or may not be exposed to a corrosive plasma environment. Some examples of chamber components include a chemical vapor deposition (CVD) chamber, a physical vapor deposition (PVD) chamber, an ALD chamber, an IAD chamber, an etch chamber, and other types of processing chambers. In some embodiments, processing chamber101may be any chamber used in an electronic device manufacturing system.

In one embodiment, the processing chamber101includes a chamber body102and a showerhead130that encloses an interior volume106. The showerhead130may include a showerhead base and a showerhead gas distribution plate (GDP), which may have multiple gas delivery holes132(also referred to herein as channels) throughout the GDP. Alternatively, the showerhead130may be replaced by a lid and a nozzle in some embodiments, or by multiple pie shaped showerhead compartments and plasma generation units in other embodiments. The chamber body102may be fabricated from aluminum, stainless steel, or other suitable material such as titanium. The chamber body102generally includes sidewalls108and a bottom110.

An outer liner116may be disposed adjacent the sidewalls108to protect the chamber body102. The outer liner116may be fabricated to include one or more apertures. In one embodiment, the outer liner116is fabricated from aluminum oxide.

An exhaust port126may be defined in the chamber body102, and may couple the interior volume106to a pump system128. The pump system128may include one or more pumps and throttle valves utilized to evacuate and regulate the pressure of the interior volume106of the processing chamber101.

The gas source160may be coupled to the processing chamber101to provide process and/or cleaning gases via supply line112to the interior volume106through a showerhead130. The flow control apparatus (e.g., gas stick200) may be coupled to the gas source160and processing chamber101. The flow control apparatus may be used to measure and control the flow of gas from the gas source160to interior volume106. An exemplary flow control apparatus is described in greater detail below with respect toFIGS.2A-2B. In some embodiments, a flow control apparatus includes a gas flow valve having a first valve portion and a second valve portion as described herein. In some embodiments, one or more gas panels160may be coupled to processing chamber101to provide gases to the interior volume106. In such embodiments, one or more flow control systems may be coupled to each gas source160and processing chamber101. In other embodiments, a single flow control apparatus may be coupled to one or more gas panels160. In some embodiments, the flow control apparatus may comprise a flow ratio controller to control the flow of gases to the processing chamber101(e.g., through one or more supply lines112), or to other processing chambers.

In some embodiments, a separate flow control apparatus is used for each gas supplied to the processing chamber. In embodiments, each flow control apparatus is or includes a gas stick assembly200, as described and illustrated below with respect toFIGS.2A-2B.

The showerhead130may be supported on the sidewall108of the chamber body102. The showerhead130(or lid) may be opened to allow access to the interior volume106of the processing chamber101, and may provide a seal for the processing chamber101while closed. The gas source160may be coupled to the processing chamber101to provide process and/or cleaning gases to the interior volume106through the showerhead130or lid and nozzle (e.g., through apertures of the showerhead or lid and nozzle).

In some embodiments, one or more sensor assemblies170may be disposed within the interior volume106. For example, one or more sensor assemblies170may be located near (e.g., within 10 centimeters of) the showerhead130. As another example, one or more sensor devices may be located near (e.g., within 10 centimeters of) the substrate144, which may be used to monitor conditions near the reaction site.

In one embodiment, the substrate support assembly148includes a pedestal152that supports an electrostatic chuck150. The electrostatic chuck150further includes a thermally conductive base and an electrostatic puck bonded to the thermally conductive base by a bond, which may be a silicone bond in one embodiment. The thermally conductive base and/or electrostatic puck of the electrostatic chuck150may include one or more optional embedded heating elements, embedded thermal isolators, and/or conduits to control a lateral temperature profile of the substrate support assembly148. The electrostatic puck may further include multiple gas passages such as grooves, mesas, and other surface features that may be formed in an upper surface of the electrostatic puck. The gas passages may be fluidly coupled to a source of a heat transfer (or backside) gas such as helium via holes drilled in the electrostatic puck. In operation, the backside gas may be provided at controlled pressure into the gas passages to enhance the heat transfer between the electrostatic puck and a supported substrate144. The electrostatic chuck150may include at least one clamping electrode controlled by a chucking power source.

FIG.2Aillustrates a schematic diagram of a gas stick assembly200in accordance with embodiments of the present disclosure. A plurality of gas stick assemblies may receive gasses from a plurality of gas supplies. For example, a processing device may include a different gas stick assembly for each type of gas that is delivered into a process chamber. As shown, gas flows from left to right through the gas stick assembly. In some embodiments, gas stick assembly200includes a hybrid valve201, which may be a first component of the gas stick assembly200. A hybrid valve may include a manual valve and a valve that can be automatically actuated (e.g., a pneumatic valve, electrical valve, etc.). Hybrid valve201may receive a gas from a gas source (not illustrated). The hybrid valve201may direct the gas to a purge valve202via one or more passages. The purge valve202may be configured to purge the gas stick assembly200. In some embodiments, gas stick assembly200includes a regulator203. The regulator203may receive the gas from the purge valve202. The regulator203may regulate the flow of the gas through the gas stick assembly200. In some embodiments, a filter204is coupled downstream of the regulator203, and receives the flow of gas from the regulator203. In some embodiments, an upstream valve205may receive the gas from the regulator203and direct the gas flow to a mass flow controller206. The mass flow controller206may control the flow of gas through the gas stick assembly200. In some embodiments, a downstream valve207receives the gas from the mass flow controller or other upstream component. The downstream valve207may direct the gas toward a gas destination (e.g., a processing chamber; not illustrated). In some embodiments, one or more of the hybrid valve201, upstream valve205, mass flow controller206, or downstream valve207include a first valve portion and a second valve portion as described herein.

FIG.2Billustrates a perspective view of a gas stick assembly200in accordance with embodiments of the present disclosure. A plurality of gas stick assemblies may receive gasses from a plurality of gas supplies. For example, a processing device may include a different gas stick assembly for each type of gas that is delivered into a process chamber. As shown, gas flows from left to right through the gas stick assembly.

In some embodiments, gas stick assembly200includes a base209. Gas stick assembly200may receive a gas (e.g., from a gas source) via gas coupling208. In some embodiments, gas stick assembly200includes hybrid valve201, purge valve202, regulator203, filter204, upstream valve205, mass flow controller206, and/or downstream valve207. In some embodiments, each of hybrid valve201, purge valve202, regulator203, filter204, upstream valve205, mass flow controller206, and/or downstream valve207are coupled to a gas stick assembly base209.

FIG.3is a cutaway view of a fluid flow valve300in accordance with embodiments of the present disclosure. In some embodiments, a fluid (e.g., such as a gas) is introduced at inlet332. One or more passages within the base304guide the fluid to inner poppet312and/or outer poppets314. In some embodiments, inner poppet312makes up a first valve portion and outer poppets314make up a second valve portion. In some embodiments, outer poppets314is an annular poppet that surrounds inner poppet312. In some embodiments, outer poppets314form a radial portion surrounding the inner poppet312. In some embodiments, diaphragm310forms dual poppets. For example, the diaphragm forms the inner poppet312and the outer poppets314. In some embodiments, inner poppet312is disposed at a lower height than outer poppets314as described in more detail with respect toFIGS.7A-7C. In some embodiments, the poppet seats (e.g., for inner poppet312and/or outer poppets314) are coated with a polymer to achieve tighter leak rates. In some embodiments, the inner poppet312and/or the outer poppets314are made of a polymer material. Example polymers may include perfluoroalkoxy alkane (PFA) or polychlorotrifluoroethylene (PCTFE). In some embodiments, diaphragm310is coated with a corrosion-resistant coating. In some embodiments, diaphragm310is made of a material such as stainless steel or an alloy of nickel (e.g., a corrosion resistant nickel alloy, hastelloy, etc.). In some embodiments, diaphragm310may be curved to enhance displacement. In some embodiments, diaphragm310may be corrugated.

In some embodiments, an actuator306causes diaphragm310to move responsive to receiving an input signal from controller380. For example, controller380may send an electrical signal to the actuator306to open inner poppet312and/or outer poppet314. The diaphragm310may flex and/or un-flex to open or close the poppet(s). The electrical signal from the controller380may cause the actuator306to move (e.g., flex or un-flex) the diaphragm310which causes inner poppet312and/or outer poppet314to open or close to control flow of fluid. In some embodiments, the actuator306causes the diaphragm310to flex by pushing or pulling on the diaphragm310proximate the center of the diaphragm310. When at least one of the poppets are open, the fluid may flow through the poppet(s) and out of the housing through fluid outlet334. In some embodiments, a signal from the controller380causes the actuator306to proportionally control the flow of fluid through the poppet(s). The controller380can send an electrical signal to the actuator306to move the diaphragm (e.g., to move the poppet(s)) to control the flow of fluid through the valve. In some embodiments, the actuator306preloads the diaphragm310so that fluid does not leak.

In some embodiments, the actuator306is disposed within a housing302that is coupled to the base304. In some embodiments, the joint between the housing302and the base304is sealed, such as with a metal seal or a gasket. In some embodiments, the housing302is coupled to the base304by one or more mechanical fasteners and/or by welding. In some embodiments, a ring308in the housing302centers the actuator within the housing302. In some embodiments, the ring308is a rubber ring such as an o-ring. In some embodiments, the actuator306is selected from a group including an electric solenoid actuator, a voice coil actuator, or a ferrofluidic actuator. In some embodiments, where the flow of fluid is at high temperature, the actuator306is a ferrofluidic actuator because of the high temperature tolerance of ferrofluidic actuators. In some embodiments, a voice coil actuator can provide a constant force on the diaphragm310over the full range of motion.

In some embodiments, a strain gauge322is coupled to the diaphragm310. The strain gauge322may be attached to the diaphragm310by one or more fasteners and/or by a bonding adhesive. Strain gauge322may be attached on a top side of diaphragm310away from the flow of fluid. In some embodiments, strain gauge322is annularly shaped. The strain gauge322may surround the center of the diaphragm310where the actuator306contacts the diaphragm310. In some embodiments, the strain gauge322can sense the flexing of the diaphragm310when actuated by actuator306. Strain gauge322may provide direct measurement of the deformation (e.g., flexing or un-flexing) of diaphragm310. Strain gauge322may measure displacement of the diaphragm. In some embodiments, controller380uses displacement data from strain gauge322to determine how far the diaphragm310has been moved by the actuator306. In some embodiments, the controller380causes actuation of the diaphragm310based on displacement data from the strain gauge322. For example, the controller380may output an electrical signal to the actuator306to actuate the diaphragm310to a first position. The strain gauge322may indicate to the controller380that the diaphragm310has instead been actuated to a different second position. The controller380may update the signal to the actuator306based on data from the strain gauge322to actuate the diaphragm310to the first position.

FIGS.4A-4Bare cutaway views of fluid flow valves in accordance with embodiments of the present disclosure. Referring toFIG.4A, a side cutaway view of a fluid flow valve400A in accordance with embodiments of the present disclosure is shown. In some embodiments, diaphragm310is actuated by an actuator406disposed within a housing402. In some embodiments, actuator406is a piezoelectric-based actuator such as a multi-stack piezoelectric actuator. A multi-stack piezoelectric actuator may include multiple piezoelectric actuators stacked on top of one another. In some embodiments, actuator406(e.g., a multi-stack piezoelectric actuator) can apply greater force than actuator306(e.g., a solenoid actuator, a voice coil actuator, a ferrofluidic actuator, etc.). Therefore, actuator406can be used where fluid inlet pressures are higher than can be used with actuator306. However, actuator406may be capable of a lesser range of travel compared to actuator306. In some embodiments, actuator406has a finer resolution than actuator306. In some embodiments, actuator406presses on a plunger442A to actuate the diaphragm310. Actuator406may be actuated based on an electrical signal (e.g., from a controller such as controller380). In some embodiments, actuator406can apply just a pushing force (e.g., can push downwards on plunger442A but not upwards on the plunger442A). In some embodiments, valve400A is a normally open valve.

Referring toFIG.4B, a side cutaway view of a fluid flow valve400B in accordance with embodiments of the present disclosure is shown. In some embodiments, valve400B includes a transfer mechanism to convert motion of the actuator406in a first direction into motion of the diaphragm in an opposite second direction. In some embodiments, the transfer mechanism converts a ‘push’ force of actuator406into a ‘pull’ force on diaphragm310. In some embodiments, a transfer mechanism includes a disc spring (e.g., a fulcrum disc spring) and/or an adapter. In some embodiments, a disc spring includes a conical spring with a fulcrum to convert ‘push’ force of actuator406into a ‘pull’ force. In some embodiments, actuator406is coupled to an adapter446which is coupled to plunger442B. Because actuator406may be capable of applying just a pushing force (e.g., can push downwards), actuator406is coupled to adapter446to cause diaphragm310to move upwards (e.g., via plunger442B). In some embodiments, responsive to an electrical signal (e.g. from a controller such as controller380), actuator406actuates to exert a force on plate444, causing actuator406to move upwards, lifting adapter446and plunger442B. The lifting of plunger442B causes diaphragm310to flex so that poppet(s)312,314can open to flow fluid. In some embodiments, actuator406allows diaphragm310to un-flex (e.g., closing poppet(s)312,314, allowing plunger442B and adapter446to move downwards) responsive to receiving the corresponding control signal. In some embodiments, valve400B is a normally closed valve.

FIG.5Ais a cutaway view of a fluid flow valve500in accordance with embodiments of the present disclosure.FIG.5Bis a perspective view of a flexure poppet member510in accordance with embodiments of the present disclosure. Referring toFIG.5A, valve500includes an actuator506within a housing502that is coupled to base504. In some embodiments, actuator506is a multi-stack piezoelectric actuator similar to actuator406ofFIGS.4A and4B. In some embodiments, actuator506can apply a pushing (e.g., downwards) force on a plunger542. The plunger542can in turn push downwards (e.g., when pushed on by actuator506) on the tip512of a flexure poppet member510. In some embodiments, tip512forms a seal with an inner surface of base504when flexure poppet member510is in a natural position (e.g., an un-flexed state) so that fluid cannot pass. In some embodiments, when actuator506is caused to push (e.g., downwards) on plunger542, flexure poppet member510is pushed downwards to allow fluid to pass by tip512. In some embodiments, the outer portion of flexure poppet member510flexes when tip512is pushed by plunger542. In some embodiments, fluid is allowed to flow from fluid inlet532, through multiple holes513formed in the outer portion of the flexure poppet member510, past tip512, and out of the base504through fluid outlet534. A diaphragm515may seal around plunger542to isolate the actuator506from flowing fluid and to prevent leaks. The outer edge of diaphragm515may coupled to the base504and the inner edge of diaphragm515may be coupled to the plunger542. The diaphragm515may flex with the motion of plunger542. In some embodiments, an outer rim of flexure poppet member510holds the flexure poppet member510in place within the base504when flexed by the pushing of actuator506(e.g., via plunger542). In some embodiments, flexure poppet member510is made of a polymer. In some embodiments, flexure poppet member510acts as a spring to keep the poppet normally closed, yet allowing fluid flow when pushed by actuator506.

FIG.6is a cutaway view of a fluid flow valve600in accordance with embodiments of the present disclosure. In some embodiments, a bending piezo actuator606is coupled to diaphragm310. Bending piezo actuator606may be coupled to a top side of diaphragm310away from the flow of fluid. Bending piezo actuator606may be coupled to diaphragm310by one or more mechanical fasteners and/or by adhesive bonding. Strain gauge322may be coupled on top of bending piezo actuator606. Bending piezo actuator606may have a higher displacement than multi-stack piezo electric actuator406but may be capable of exerting a lesser force than actuator406. In some embodiments, bending piezo actuator606may bend responsive to receiving a control signal (e.g., an electrical signal from a controller such as controller380). In some embodiments, bending piezo actuator606may be a bimorph actuator. In some embodiments, bending piezo actuator606includes multiple bending piezo actuators stacked one on top of the other. In some embodiments, the bending of bending piezo actuator606causes diaphragm310to flex and/or un-flex so that poppet(s)312,314can be opened and/or closed. In some embodiments, one or more springs652within housing602pushes on bending piezo actuator606to cause diaphragm310to move to a closed position (e.g., closing poppet(s)312,314) when bending piezo actuator606relaxes responsive to receiving a corresponding control signal (e.g., from the controller). In some embodiments, spring(s)652are coil springs.

FIGS.7A-7Care cutaway views of a dual poppet valve diaphragm in accordance with embodiments of the present disclosure.FIG.7Ashows the dual poppet valve diaphragm in a closed position.FIG.7Bshows the dual poppet valve diaphragm in a partially open position.FIG.7Cshows the dual poppet valve diaphragm in a fully open position. Referring toFIG.7A, inner poppet712and outer poppet(s)714are shown in a closed position. In some embodiments, when the poppet(s) are closed, no fluid can flow through the poppet(s). In some embodiments, inner poppet712and outer poppet(s)714form sealing surfaces on a first side (e.g., a bottom side) of diaphragm710. In some embodiments, inner poppet712and outer poppet(s)714are made of a polymer. In some embodiments, outer poppet(s)714are an annular poppet that surrounds inner poppet712. In some embodiments, outer poppet(s)714are separate poppets disposed proximate the edges of diaphragm710while inner poppet712is disposed substantially at the center of diaphragm710. In some embodiments, inner poppet712is disposed vertically lower than outer poppet(s)714.

Referring toFIG.7B, inner poppet712is shown in an open position while outer poppet(s)714remain in a closed position. In some embodiments, diaphragm710can be actuated to this position (e.g., by an actuator such as actuator306,406,606, etc.) to allow less than a threshold amount of fluid to flow through the inner poppet712. In some embodiments, diaphragm710is actuated to the partially open position (e.g., to open inner poppet712while keeping outer poppet(s)714closed) to accomplish a “soft start” of the flow of fluid through the valve. Precise metering of small amounts of fluid flow can be accomplished by actuating diaphragm710to open and/or close inner poppet712while keeping outer poppet(s)714closed. Control of inner poppet712may control “lift off” of the diaphragm710to precisely control small amount of fluid flow.

Referring toFIG.7C, both inner poppet712and outer poppet(s)714are shown in an open position. In some embodiments, diaphragm710can be actuated to this fully open position to flow more than a threshold amount of fluid. In some embodiments, outer poppet(s)714can be opened after inner poppet712is fully opened. Thus, the diaphragm710having an inner poppet712and outer poppet(s)714may provide a two-stage poppet design. In some embodiments, outer poppet(s)714can flow a substantially greater amount of fluid than inner poppet712. By controlling the flow of fluid through inner poppet712and outer poppet(s)714, a wide range of fluid flow can be controlled with high precision.

FIGS.8A-8Bare flow diagrams of methods of controlling a fluid flow valve in accordance with embodiments of the present disclosure.FIG.8Ais a flow diagram of a method800A for controlling a fluid flow valve such as fluid flow valve300,400A,400B,500, or600in accordance with embodiments of the present disclosure. In some embodiments, method800A is performed and/or caused to be performed by processing logic that includes hardware (e.g., circuitry, dedicated logic, programmable logic, microcode, processing device, etc.), software (such as instructions run on a processing device, a general purpose computer system, or a dedicated machine), firmware, microcode, or a combination thereof. In some embodiments, method800A is performed, at least in part, by a controller a gas flow valve assembly (e.g., controller380, etc.).

For simplicity of explanation, method800A is depicted and described as a series of operations. However, operations in accordance with this disclosure can occur in various orders and/or concurrently and with other operations not presented and described herein. Furthermore, in some embodiments, not all illustrated operations are performed to implement method800A in accordance with the disclosed subject matter. In addition, those skilled in the art will understand and appreciate that method800A could alternatively be represented as a series of interrelated states via a state diagram or events.

In some embodiments, at block802, processing logic receives target flow data associated with a flow of fluid through a valve. In some embodiments, the valve has a first valve portion and a second valve portion in parallel with one another within a housing of the valve. The target flow data may correspond to one or more target fluid flow rates (e.g., target gas flow rates) for one or more process recipe operations (e.g., substrate process recipe operations). In some embodiments, the target flow data may indicate that a fluid is to be supplied at a first flowrate for a first duration of time and that the fluid is to be supplied at a different second flowrate for a second duration of time. In some embodiments, the target flow data may indicate that the fluid is to be supplied at a fluctuating flowrate and/or a changing flowrate over time.

In some embodiments, at block804, processing logic causes a diaphragm to actuate to one or more first open positions to flow a first amount of fluid through the first valve portion. Causing the diaphragm to actuate to the one or more first open positions may include causing the diaphragm to flex and/or move up to a threshold position. Causing the diaphragm to actuate to the one or more first open positions may be based at least in part on the target flow data (e.g., received at block802). In some embodiments, the diaphragm is caused to actuate (e.g., by an actuator) to open an inner poppet of a dual poppet system to flow the first amount of fluid. In some embodiments, the first amount of fluid is less than a threshold amount of fluid. In some embodiments, the inner poppet is caused to open (e.g., by actuating the diaphragm) to perform a fluid flow “soft start.” For example, the flow of fluid is slowly initiated by controlling the rate at which the inner poppet is opened by causing the diaphragm to actuate. One or more outer poppets of the dual poppet system may remain closed when the diaphragm is actuated to the one or more first open positions so that less than the threshold amount of fluid can flow through the valve (e.g., via the open inner poppet).

In some embodiments, at block806, processing logic causes the diaphragm to actuate to one or more second open positions to flow a greater second amount of fluid through at least the second valve portion. Causing the diaphragm to actuate to the one or more second open positions may include causing the diaphragm to flex and/or move beyond a threshold position. Causing the diaphragm to actuate to the one or more second open positions may be based at least in part on the target flow data (e.g., received at block802). In some embodiments, the diaphragm is caused to actuate to open one or more outer poppets of a dual poppet system to flow the second amount of fluid. In some embodiments, the second amount of fluid is greater than a threshold amount of fluid. In some embodiments, the one or more outer poppets is caused to open to flow a larger amount of fluid than at block804. The inner poppet of the dual poppet system may remain open when the diaphragm is actuated to the one or more second open positions. Fluid flow through the inner poppet may be combined with fluid flow through the one or more outer poppets when the diaphragm is opened to the one or more second open positions.

FIG.8Bis a flow diagram of a method800B for controlling a fluid flow valve such as fluid flow valve300,400A,400B,500, or600in accordance with embodiments of the present disclosure. In some embodiments, method800B is performed and/or caused to be performed by processing logic that includes hardware (e.g., circuitry, dedicated logic, programmable logic, microcode, processing device, etc.), software (such as instructions run on a processing device, a general purpose computer system, or a dedicated machine), firmware, microcode, or a combination thereof. In some embodiments, method800B is performed, at least in part, by a controller a gas flow valve assembly (e.g., controller380, etc.).

For simplicity of explanation, method800B is depicted and described as a series of operations. However, operations in accordance with this disclosure can occur in various orders and/or concurrently and with other operations not presented and described herein. Furthermore, in some embodiments, not all illustrated operations are performed to implement method800B in accordance with the disclosed subject matter. In addition, those skilled in the art will understand and appreciate that method800B could alternatively be represented as a series of interrelated states via a state diagram or events.

In some embodiments, at block812, processing logic receives flow data associated with flow of fluid from one or more flow sensors. In some embodiments, the flow data corresponds to a mass flow rate and/or a volumetric flow rate of a gas flowing in a gas distribution system.

In some embodiments, at block814, processing logic causes a diaphragm (e.g., of a valve) to actuate based at least in part on the flow data (e.g., received at block812) and a target fluid flow rate. In some embodiments, the target fluid flow rate is associated with one or more process recipe operations. In some embodiments, the diaphragm is caused to actuated so that the measured fluid flow rate (e.g., measured by the one or more flow sensors) substantially matches the target fluid flow rate. In some embodiments, actuating the diaphragm causes dual poppets to open and/or close to control the fluid flow rate.

In some embodiments, at block816, processing logic receives displacement data from a strain gauge bonded to the diaphragm. In some embodiments, the strain gauge measures deflection of the diaphragm. A processing device (e.g., of a controller) can determine the position of the diaphragm based on the data from the strain gauge.

In some embodiments, at block818, processing logic causes the diaphragm to actuate further based on the displacement data (e.g., received at block816). In some embodiments, the diaphragm is caused to actuate to a target position. A difference between the target position and the current displacement of the diaphragm (e.g., indicated in the displacement data) may be determined and the diaphragm caused to actuate to eliminate the difference.

In some embodiments, the diaphragm is caused to actuate based on one or more outputs from a trained machine learning model. The trained machine learning model may be trained to output an optimized control scheme using historical actuation data for controlling the valve. In some embodiments, a machine learning model is trained with historical actuation data associated with actuation of the diaphragm and historical flow data associated with the flow of fluid to form the trained machine learning model. In some embodiments, based on historical flow data, the trained machine learning model can predict actuation value(s) (e.g., positions of the diaphragm) to actuate the diaphragm to optimize the flow of fluid. In some embodiments, processing logic inputs target flowrate data and/or measured flowrate data into the trained machine learning model. The trained machine learning model may output one or more actuation values associated with a predicted fluid flow rate and/or predicted diaphragm position to optimize the flow of fluid.

The exemplary computer system900includes a processing device (processor)902, a main memory904(e.g., ROM, flash memory, dynamic random access memory (DRAM) such as synchronous DRAM (SDRAM) or Rambus DRAM (RDRAM), etc.), a static memory906(e.g., flash memory, static random access memory (SRAM), etc.), and a data storage device920, which communicate with each other via a bus910.

Processor902represents one or more general-purpose processing devices such as a microprocessor, central processing unit, or the like. More particularly, the processor902may be a complex instruction set computing (CISC) microprocessor, reduced instruction set computing (RISC) microprocessor, very long instruction word (VLIW) microprocessor, or a processor implementing other instruction sets or processors implementing a combination of instruction sets. The processor902may also be one or more special-purpose processing devices such as an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a digital signal processor (DSP), network processor, or the like. The processor902is configured to execute instructions940for performing the operations discussed herein.

The computer system900may further include a network interface device908. The computer system900also may include a video display unit912(e.g., a liquid crystal display (LCD), a cathode ray tube (CRT), or a touch screen), an alphanumeric input device914(e.g., a keyboard), a cursor control device916(e.g., a mouse), and a signal generation device922(e.g., a speaker).

Power device918may monitor a power level of a battery used to power the computer system900or one or more of its components. The power device918may provide one or more interfaces to provide an indication of a power level, a time window remaining prior to shutdown of computer system900or one or more of its components, a power consumption rate, an indicator of whether computer system is utilizing an external power source or battery power, and other power related information. In some implementations, indications related to the power device918may be accessible remotely (e.g., accessible to a remote back-up management module via a network connection). In some implementations, a battery utilized by the power device918may be an uninterruptable power supply (UPS) local to or remote from computer system900. In such implementations, the power device918may provide information about a power level of the UPS.

The data storage device920may include a computer-readable storage medium924(e.g., a non-transitory computer-readable storage medium) on which is stored one or more sets of instructions940(e.g., software) embodying any one or more of the methodologies or functions described herein. These instructions940may also reside, completely or at least partially, within the main memory904and/or within the processor902during execution thereof by the computer system900, the main memory904, and the processor902also constituting computer-readable storage media. The instructions940may further be transmitted or received over a network930via the network interface device908. While the computer-readable storage medium924is shown in an exemplary implementation to be a single medium, it is to be understood that the computer-readable storage medium924may include a single medium or multiple media (e.g., a centralized or distributed database, and/or associated caches and servers) that store the one or more sets of instructions940.

In the foregoing description, numerous details are set forth. It will be apparent, however, to one of ordinary skill in the art having the benefit of this disclosure, that the present disclosure may be practiced without these specific details. While specific embodiments have been described herein, it should be understood that they have been presented by way of example only, and not limitation. The breadth and scope of the present application should not be limited by any of the embodiments described herein, but should be defined only in accordance with the following and later-submitted claims and their equivalents. Indeed, other various implementations of and modifications to the present disclosure, in addition to those described herein, will be apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such other implementations and modifications are intended to fall within the scope of the present disclosure.

References were made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments. Although these disclosed embodiments are described in sufficient detail to enable one skilled in the art to practice the embodiments, it is to be understood that these examples are not limiting, such that other embodiments may be used and changes may be made to the disclosed embodiments without departing from their spirit and scope. For example, the blocks of the methods shown and described herein are not necessarily performed in the order indicated in some other embodiments. Additionally, in some other embodiments, the disclosed methods may include more or fewer blocks than are described. As another example, some blocks described herein as separate blocks may be combined in some other embodiments. Conversely, what may be described herein as a single block may be implemented in multiple blocks in some other embodiments. Additionally, the conjunction “or” is intended herein in the inclusive sense where appropriate unless otherwise indicated; that is, the phrase “A, B, or C” is intended to include the possibilities of “A,” “B,” “C,” “A and B,” “B and C,” “A and C,” and “A, B, and C.”

The words “example” or “exemplary” are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as an “example” or “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Rather, use of the words “example” or “exemplary” is intended to present concepts in a concrete fashion. When the term “about” or “approximately” is used herein, this is intended to mean that the nominal value presented is precise within ±10%.

In addition, the articles “a” and “an” as used herein and in the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form. Reference throughout this specification to “an embodiment,” “one embodiment,” “some embodiments,” or “certain embodiments” indicates that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrase “an embodiment,” “one embodiment,” “some embodiments,” or “certain embodiments” in various locations throughout this specification are not necessarily all referring to the same embodiment.

It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the following discussion, it is appreciated that throughout the description, discussions utilizing terms such as “receiving,” “retrieving,” “transmitting,” “computing,” “generating,” “processing,” “reprocessing,” “adding,” “subtracting,” “multiplying,” “dividing,” “optimizing,” “calibrating,” “detecting,” “performing,” “analyzing,” “determining,” “enabling,” “identifying,” “modifying,” “transforming,” “applying,” “causing,” “storing,” “comparing,” or the like, refer to the actions and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (e.g., electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission, or display devices.

Furthermore, although the present disclosure has been described herein in the context of a particular implementation in a particular environment for a particular purpose, those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the present disclosure may be beneficially implemented in any number of environments for any number of purposes. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the present disclosure as described herein, along with the full scope of equivalents to which such claims are entitled.