Abstract:
A transfer chamber for semiconductor device manufacturing includes (1) a plurality of sides that define a region configured to maintain a vacuum level and allow transport of substrates between processing chambers, the plurality of sides defining a first portion and a second portion of the transfer chamber and including (a) a first side that couples to two twinned processing chambers; and (b) a second side that couples to a single processing chamber; (2) a first substrate handler located in the first portion of the transfer chamber; (3) a second substrate handler located in the second portion of the transfer chamber; and (4) a hand-off location configured to allow substrates to be passed between the first portion and the second portion of the transfer chamber using the first and second substrate handlers. Method aspects are also provided.

Description:
RELATED APPLICATIONS 
       [0001]    The present application claims priority to U.S. Provisional Application 61/778,206 filed Mar. 12, 2013, and entitled “SEMICONDUCTOR DEVICE MANUFACTURING PLATFORM WITH SINGLE AND TWINNED PROCESSING CHAMBERS” (Attorney Docket No. 17480/L), which is hereby incorporated herein for all purposes. 
     
    
     FIELD 
       [0002]    The present invention relates to semiconductor device manufacturing, and more specifically to a semiconductor device manufacturing platform with single and twinned processing chambers. 
       BACKGROUND 
       [0003]    Manufacturing of semiconductor devices typically involves performing a sequence of procedures with respect to a substrate or “wafer” such as a silicon substrate, a glass plate, etc. These steps may include polishing, deposition, etching, photolithography, heat treatment, and so forth. Usually a number of different processing steps may be performed in a single processing system or “tool” which includes a plurality of processing chambers or “reactors”. 
         [0004]    To reduce semiconductor device manufacturing costs, methods and apparatus for improving efficiency and/or reducing cost of operation of processing tools are desired. 
       SUMMARY 
       [0005]    In some embodiments, a transfer chamber configured for use during semiconductor device manufacturing is provided. The transfer chamber includes (1) a plurality of sides that define a region configured to maintain a vacuum level and allow transport of substrates between a plurality of processing chambers, the plurality of sides defining a first portion of the transfer chamber and a second portion of the transfer chamber and including (a) a first side that couples to two twinned processing chambers; and (b) a second side that couples to a single processing chamber. The transfer chamber also includes (2) a first substrate handler located in the first portion of the transfer chamber; (3) a second substrate handler located in the second portion of the transfer chamber; and (4) a hand-off location configured to allow substrates to be passed between the first portion of the transfer chamber and the second portion of the transfer chamber using the first substrate handler and the second substrate handler. 
         [0006]    In some embodiments, a method is provided that includes (a) providing a transfer chamber having a plurality of sides that define a region configured to maintain a vacuum level and allow transport of substrates between a plurality of processing chambers, the plurality of sides defining a first portion of the transfer chamber and a second portion of the transfer chamber and including a first side coupled to two twinned processing chambers and a second side coupled to a single processing chamber; a first substrate handler located in the first portion of the transfer chamber; a second substrate handler located in the second portion of the transfer chamber; and a hand-off location configured to allow substrates to be passed between the first portion of the transfer chamber and the second portion of the transfer chamber using the first substrate handler and the second substrate handler; (b) loading a first substrate into the transfer chamber employing the first substrate handler; (c) transferring the first substrate to the hand-off location; (d) retrieving the first substrate from the hand-off location with the second substrate handler; (e) loading a second substrate into the transfer chamber employing the first substrate handler; and (f) simultaneously loading the first and second substrates into the twinned processing chambers coupled to the first side of the transfer chamber using the first and second substrate handlers. 
         [0007]    In some embodiments, a transfer chamber configured for use during semiconductor device manufacturing is provided. The transfer chamber includes (1) a plurality of sides that define a region configured to maintain a vacuum level and allow transport of substrates between a plurality of processing chambers, the plurality of sides including (a) a first, elongated side that couples to two twinned processing chambers; (b) a second side that couples to a single processing chamber; and (c) a third side that couples to a load lock chamber. The transfer chamber also includes (2) an extended-reach substrate handler located in the transfer chamber and configured to transport substrates between the load lock chamber, twinned processing chambers and single processing chamber; and (3) a hand-off location configured to provide on or more of a transfer location, substrate storage, chuck cover storage, cool-down, substrate heating, pre-processing and post-processing. Numerous other embodiments are provided. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0008]      FIG. 1  illustrates a top schematic view of an example processing tool provided in accordance with embodiments of the invention. 
           [0009]      FIG. 2  illustrates a partial cross-sectional view of the hand-off locations of  FIG. 1  taken along line  2 - 2  of  FIG. 1  in accordance with embodiments of the invention. 
           [0010]      FIG. 3  illustrates a top schematic view of another example processing tool provided in accordance with embodiments of the invention. 
           [0011]      FIG. 4  illustrates a flowchart of an example method of operating the processing tool of  FIG. 1  in accordance with embodiments of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0012]    In accordance with embodiments of the present invention, a semiconductor device manufacturing platform, such as a tool and/or mainframe, is provided that may allow both single processing chambers and dual or “twinned” processing chambers to be employed. Twinned processing chambers may provide reduce operation costs by sharing resources such as chemical and/or gas delivery, process control, and the like. In some embodiments, the manufacturing platform may support up to six processing chambers with either two or four of the processing chambers being twinned. Other configurations may be employed. 
         [0013]    In one or more embodiments, hand-off locations are provided within the tool that allows substrates to be passed from one portion of the tool to another portion of the tool. In some embodiments, these hand-off locations may provide active pre- and/or post-processing. These and other embodiments of the invention are described below with reference to  FIGS. 1-4 . 
         [0014]      FIG. 1  is a top schematic view of an example processing tool  100  provided in accordance with embodiments of the invention. With reference to  FIG. 1 , the tool  100  includes a transfer chamber  102  having a plurality of sides  104   a - 104   h  (forming an octagonal shaped transfer chamber). Other shapes and/or numbers of sides may be employed (e.g., forming a closed polygon). 
         [0015]    In the embodiment of  FIG. 1 , sides  104   a  and  104   d  are elongated to allow coupling of twinned processing chambers  106   a,    106   b  along side  104   a  and twinned processing chambers  108   a,    108   b  along side  104   d.  Other configurations may be employed, such as coupling non-twinned or “single” processing chambers along the side  104   a  and/or  104   d.  In some embodiments, the lengths for the elongated sides  104   a ,  104   d  of transfer chamber  102  that couple to twinned processing chambers may be about 1100 mm to about 2500 mm. Other lengths may be employed for the elongated sides  104   a  and/or  104   d.    
         [0016]    Twinned processing chambers  106   a,    106   a  may share resources such as chemical and/or gas delivery, process control, and the like (indicated generally by reference numeral  110 ). For example, such processing chambers may perform the same process recipe on two substrates simultaneously in some embodiments. Similarly, twinned processing chambers  108   a,    108   b  may share resources such as chemical and/or gas delivery, process control, and the like (indicated generally by reference numeral  112 ). 
         [0017]    Single processing chambers  114  and/or  116  may be coupled to sides  104   b  and/or  104   c  of transfer chamber  102 . In some embodiments, the lengths of the sides  104   b,    104   c  of transfer chamber  102  to which single processing chambers couple may be about 550 mm to about 2500 mm. Other lengths for the sides  104   b  and/or  104   c  may be employed. Single processing chambers typically employ their own resources such as chemical and/or gas delivery, process control, etc. (not shown). Fewer or more processing chambers may be coupled to the transfer chamber  102 . 
         [0018]    In some embodiments, load lock chambers  118   a,    118   b  may couple to sides  104   f,    104   g  of transfer chamber  102 , respectively. Load lock chambers  118   a,    118   b  allow substrates to be supplied to transfer chamber  102  from substrate carriers  120   a,    120   b  via a factory interface  122 . Load lock chambers  118   a,    118   b  may be, for example, batch load locks, stacked single substrate load locks or other suitable load locks. 
         [0019]    In the embodiment of  FIG. 1 , the transfer chamber  102  includes two substrate handlers  124   a,    124   b  for transferring substrates to and from the load locks  118   a ,  118   b,  and to and from one or more of the processing chambers  106   a,    106   b,    108   a,    108   b,    114  and/or  116 . For example, first substrate handler  124   a  may transfer substrates to and/or from one or more of the load locks  118   a,    118   b  and processing chambers  106   a,    108   a  (within a first portion  126   a  of transfer chamber  102 ); and second substrate handler  124   b  may transfer substrates to and/or from one or more of processing chambers  106   b,    108   b,    114  and  116  (within a second portion  126   b  of transfer chamber  102 ). Substrate handlers  124   a,    124   b  may be single or dual blade robots, for example, that carry one or more substrates. 
         [0020]    Substrates may be passed between first and second portions  126   a,    126   b  of transfer chamber  102  through use of one or more hand-off locations  128   a,    128   b.  While two hand-off locations are shown in  FIG. 1 , it will be understood that fewer or more hand-off locations may be employed (e.g.,  1 ,  3 ,  4 ,  5 , etc.). To transfer a substrate from the first portion  126   a  of transfer chamber  102  to the second portion  126   b  of transfer chamber  102 , the first substrate handler  124   a  may place the substrate on hand-off location  128   a  or  128   b  and the second substrate handler  124   b  may retrieve the substrate from the hand-off location  128   a  or  128   b.  The reverse process may be performed to transfer substrates from the second portion  126   b  to the first portion  126   a  of the transfer chamber  102 . 
         [0021]    A controller  130  may be employed to control operation of the processing tool  100 . For example, controller  130  may control substrate transfers to, from and/or within the processing tool  100 , operation of one or more of the processing chambers  106   a,    106   b,    108   a,    108   b,    114 ,  116 , operation of load locks  118   a,    118   b,  etc. Controller  130  may be an appropriately programmed microprocessor or microcontroller, hardware circuitry, a combination thereof, etc. The controller  130  may contain computer program code for performing any of the methods described herein. 
         [0022]      FIG. 2  is a partial cross-sectional view of the hand-off locations  128   a,    128   b  of  FIG. 1  taken along line  2 - 2  of  FIG. 1 . Hand-off locations  128   a,    128   b  may include pedestals or supports  200   a,    200   b  for supporting a substrate being transferred between substrate handlers  124   a  and  124   b . In the embodiment shown, the supports  200   a,    200   b  are positioned near a bottom of transfer chamber  102 . However, the supports  200   a,    200   b  may be positioned at any other location such as in the middle or at the top of transfer chamber  102  and/or at different locations. Other numbers of hand-off locations and/or supports may be employed (e.g., 1, 3, 4, 5, etc.). 
         [0023]    Supports  200   a,    200   b  may be formed from glass, aluminum, ceramic or another suitable material. If desired, lift pins (not shown) may be employed to raise and/or lower substrates relative to the supporting surface of supports  200   a,    200   b.    
         [0024]    In some embodiments, hand-off locations  128   a,    128   b  may include processing regions  202   a  and  202   b  configured to perform one or more processes on substrates within the hand-off locations  128   a,    128   b.  Example processes include pre- and/or post processing such as degas, annealing, cool down, plasma treatment, or the like. Other processes and/or numbers of processing regions  202   a  and  202   b  may be employed. 
         [0025]    In the embodiment of  FIG. 2 , the processing regions  202   a,    202   b  are positioned at an elevation above the supports  200   a,    200   b.  In other embodiments, the processing regions  202   a,    202   b  may be located below the supports  200   a ,  200   b  or at another suitable elevation relative to the supports  200   a,    200   b.    
         [0026]    In some embodiments, processing regions  202   a,    202   b  may include heaters  204   a,    204   b  for heating substrates loaded into the processing regions  202   a,    202   b.  Lift pins  206   a ,  206   b  may be employed to lower substrates onto and/or lifting substrates from the heaters  204   a,    204   b,  respectively (e.g., with linear or other motors  208   a,    208   b ). 
         [0027]    In one or more embodiments, shields  210   a,    210   b  may be employed to isolate the environment within the processing regions  202   a,    202   b  from other portions of the transfer chamber  102 . For example, the shields  210   a,    210   b  may be formed from a metal such as aluminum, stainless steel or any other suitable material. If desired, the shields  210   a  and  210   b  may form a vacuum seal between the heaters  204   a,    204   b  and the remainder of transfer chamber  102  and/or form a separately controllable environment. The shields  210   a,    210   b  may be raised and/or lowered to allow substrates to be placed within and/or removed from processing regions  202   a ,  202   b,  such as by motors  212   a,    212   b,  for example. 
         [0028]    Each processing region  202   a,    202   b  may include separate controls  214   a,    214   b  for controlling operation of the heaters  204   a,    204   b,  motors  208   a,    208   b,    212   a,    212   b , and/or delivery of any processing gasses or other resources/utilities to processing regions  202   a,    202   b.  In some embodiments, all or a portion of the controls  214   a ,  214   b  may be implemented by controller  130  of processing tool  100 . 
         [0029]    In general, hand-off location  128   a,    128   b  may be employed for substrate hand-off operations, substrate storage, chuck cover storage, cool-down, substrate heating, active pre- or post-processing, etc. 
         [0030]    In operation, substrates may be delivered to the processing tool  100  via substrate carriers  120   a  and  120   b  at factory interface  122 . A robot or other substrate handler (not shown) within the factory interface  122  may extract a substrate from one of the substrate carriers  120   a,    120   b  and deliver the substrate to load lock  118   a  or  118   b.  Substrate handler  124   a  then may extract the substrate and transfer the substrate to a desired location. For example, the substrate may be transferred to a hand-off location  128   a,    128   b  for pre-processing and/or to processing chamber  106   a  or  108   a . If the substrate is placed in the hand-off location  128   a ,  128   b,  the substrate may be returned to the first substrate handler  124   a  or transferred to second substrate handler  124   b  for processing within one or more of the processing chambers  106   b,    108   b,    114  and/or  116 . 
         [0031]    Controller  130  may be programmed to control operation of and/or substrate transfers by substrate handlers  124   a,    124   b,  as well as pre- and post-processing within hand-off locations  128   a,    128   b  (if employed). In some embodiments, substrate transfers by substrate handlers  124   a ,  124   b  may be synchronized to simultaneously load and/or unload substrates from twinned processing chambers  106   a ,  106   b  and/or  108   a,    108   b.    
         [0032]    As stated, twinned processing chambers  106   a,    106   b  and  108   a,    108   b  may share resources and thus are less expensive to operate. In some embodiments, these twinned processing chambers may employ lower throughput processes such as epitaxial grown, etch, chemical vapor deposition (CVD), or the like. Single processing chambers  114 ,  116  may employ higher throughput processes, and/or may be larger-sized processing chambers or processing chambers not well suited for twinned operation. Examples of processes that may be employed within single processing chambers  114 ,  116  include physical vapor deposition (PVD), rapid thermal processing (RTP), epitaxial growth, or the like. 
         [0033]    In some embodiments, one of the load lock chambers  118   a,    118   b  may be replaced with an additional processing chamber. Substrates may then enter and exit the processing tool  100  through a single load lock chamber. 
         [0034]      FIG. 3  is a top schematic view of an example processing tool  300  provided in accordance with embodiments of the invention. The processing tool  300  is similar to the processing tool  100  of  FIG. 1 , with substrate handlers  124   a ,  124   b  of processing tool  100  replaced with a single substrate handler  302  as shown in  FIG. 3 . In some embodiments, the single substrate handler  302  may be an extended reach robot having a reach sufficient to transfer substrates between all of the load lock chambers  118   a,    118   b  and processing chambers  106   a,    106   b,    108   a,    108   b,    114  and  116 . For example, the substrate handler  302  may be an off-axis substrate handler, a substrate handler with an extended boom  304  (as shown in  FIG. 3 ), or the like. In the embodiment of  FIG. 3 , the substrate handler  302  is a dual blade robot with blades  306   a,    306   b  that may simultaneously transport two substrates. Fewer or more blades may be employed. 
         [0035]    The processing tool  300  may operate similar to the processing tool  100  of  FIG. 1 . For example, substrates may be processed simultaneously in twinned processing chambers  106   a,    106   b  and/or  108   a,    108   b  and/or pre- or post-processed in hand-off locations  128   a,    128   b.  For example, substrates may be loaded sequentially into twinned processing chambers  106   a,    106   b  and  108   a,    108   b  in some embodiments. As stated, hand-off locations  128   a,    128   b  may be employed for substrate hand-off operations, substrate storage, chuck cover storage, cool-down, substrate heating, active pre- or post-processing, etc. 
         [0036]      FIG. 4  is a flowchart of an example method  400  of operating the processing tool  100  of  FIG. 1 . With reference to  FIG. 4 , in Block  401  a first substrate is loaded into transfer chamber  102  using first substrate handler  124   a.  In Block  402  the first substrate is transferred to one of the hand-off locations  128   a  or  128   b.  In some embodiments, the first substrate may be pre-processed while at the hand-off location  128   a  or  128   b,  such as by performing a degas or other process on the substrate. 
         [0037]    In Block  403  the second substrate handler  124   b  may retrieve the first substrate from the hand-off location  128   a  or  128   b.  Before, during or after Block  403 , the first substrate handler  124   a  may load a second substrate into the transfer chamber  102  (Block  404 ). In some embodiments, the second substrate may be pre-processed at a hand-off location  128   a  or  128   b,  such as by performing a degas or other process on the substrate. 
         [0038]    In Block  405 , the first and second substrates are loaded into the twinned processing chambers  106   a,    106   b  by substrate handlers  124   a  and  124   b.  In some embodiments this transfer may be performed simultaneously. For example, controller  130  may direct substrate handlers  124   a  and  124   b  to simultaneously load the substrates into the twinned processing chambers  106   a,    106   b  for (simultaneous) processing. In other embodiments the substrates may be (initially) transferred to the twinned processing chambers  108   a,    108   b.    
         [0039]    Following processing within the twinned processing chambers  106   a,    106   b,  the first and/or second substrate may stored, post-processed, or the like within one of the hand-off locations  128   a  or  128   b  and/or transferred to other processing chambers for further processing. The processing tool  300  of  FIG. 3  may operate similarly with regard to use of the hand-off locations  128   a  and/or  128   b.    
         [0040]    The present invention has been disclosed in connection with example embodiments thereof. It should be understood that other embodiments may fall within the spirit and scope of the invention, as defined by the following claims.