Abstract:
In a first aspect, a first mainframe is provided for use during semiconductor device manufacturing. The first mainframe includes (1) a sidewall that defines a central transfer region adapted to house a robot; (2) a plurality of facets formed on the sidewall, each adapted to couple to a process chamber; and (3) an extended facet formed on the sidewall that allows the mainframe to be coupled to at least four full-sized process chambers while providing service access to the mainframe. Numerous other aspects are provided.

Description:
The present application claims priority to U.S. Provisional Patent Application Ser. No. 60/752,459, filed Dec. 20, 2005 and entitled “EXTENDED MAINFRAME DESIGNS FOR SEMICONDUCTOR DEVICE MANUFACTURING EQUIPMENT,” which is hereby incorporated herein by reference in its entirety for all purposes. 

   FIELD OF THE INVENTION 
   The present invention relates to semiconductor device manufacturing, and more particularly to extended mainframe designs for semiconductor device manufacturing equipment. 
   BACKGROUND OF THE INVENTION 
   Semiconductor device manufacturing processes often are performed with tools having mainframes in which multiple processing chambers and/or load lock chambers are coupled around a central transfer chamber. The processing chambers may each perform unique processes, or in many instances, may perform redundant and/or related processes. 
   To ensure proper operation of a semiconductor device manufacturing tool, processing, load lock and other chambers of the tool must be maintained. Sufficient access to maintain the chambers is required. However, in some cases, providing such access may limit system throughput. 
   SUMMARY OF THE INVENTION 
   In a first aspect of the invention, a first mainframe is provided for use during semiconductor device manufacturing. The first mainframe includes (1) a sidewall that defines a central transfer region adapted to house a robot; (2) a plurality of facets formed on the sidewall, each adapted to couple to a process chamber; and (3) an extended facet formed on the sidewall that allows the mainframe to be coupled to at least four full-sized process chambers while providing service access to the mainframe. 
   In a second aspect of the invention, a system is provided for use during semiconductor device manufacturing. The system includes a mainframe having (1) a sidewall that defines a central transfer region adapted to house a robot; (2) a plurality of facets formed on the sidewall, each adapted to couple to a process chamber; and (3) an extended facet formed on the sidewall that allows the mainframe to be coupled to at least four full-sized process chambers while providing service access to the mainframe. The system also includes (a) a robot positioned within the central transfer region of the mainframe; (b) a load lock chamber coupled to a first of the plurality of facets; and (c) a process chamber coupled to the extended facet. The extended facet is adapted to increase a distance between the load lock chamber coupled to the mainframe and the process chamber coupled to the extended facet. 
   In a third aspect of the invention, a second mainframe is provided for use during semiconductor device manufacturing. The second mainframe includes a first transfer section having (1) a first sidewall that defines a first central transfer region adapted to house a first robot; (2) a plurality of facets formed on the first sidewall, each adapted to couple to a process chamber; and (3) an extended facet formed on the first sidewall that allows the mainframe to be coupled to at least four full-sized process chambers while providing service access to the mainframe. The second mainframe also includes a second transfer section coupled to the first transfer section and having (1) a second sidewall that defines a second central transfer region adapted to house a second robot; (2) a plurality of facets formed on the second sidewall, each adapted to couple to a process chamber; and (3) an extended facet formed on the second sidewall that allows the mainframe to be coupled to at least four full-sized process chambers while providing service access to the mainframe. 
   In a fourth aspect of the invention, a third mainframe is provided for use during semiconductor device manufacturing. The third mainframe includes (1) a sidewall that defines a central transfer region adapted to house a robot; (2) a plurality of facets formed on the sidewall, each adapted to couple to a process chamber; and (3) a spacer coupled to at least one of the facets, the spacer adapted to allow the mainframe to be coupled to at least four full-sized process chambers while providing service access to the mainframe. Numerous other aspects are provided in accordance with these and other aspects. 
   Other features and aspects of the present invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a top plan view of a conventional vacuum mainframe that may be employed during semiconductor device manufacturing. 
       FIG. 2  is a top plan view of the mainframe of  FIG. 1  showing four large chambers coupled to the mainframe. 
       FIG. 3A  is a top plan view of a first exemplary mainframe provided in accordance with the present invention. 
       FIG. 3B  is a top plan view of a first alternative embodiment of the mainframe of  FIG. 3A  provided in accordance with the present invention. 
       FIG. 3C  is a top plan view of a second alternative embodiment of the mainframe of  FIG. 3A  provided in accordance with the present invention. 
       FIG. 4  is a top plan view of the first exemplary mainframe of  FIG. 3A  having four large process chambers coupled to the mainframe. 
       FIG. 5A  is a top plan view of a second exemplary mainframe provided in accordance with the present invention. 
       FIG. 5B  is a top plan view of a first alternative embodiment of the mainframe of  FIG. 5A  provided in accordance with the present invention. 
       FIG. 5C  is a top plan view of a second alternative embodiment of the mainframe of  FIG. 5A  provided in accordance with the present invention. 
       FIG. 6  is a top plan view of the second exemplary mainframe of  FIG. 5A  having five large process chambers coupled to the mainframe. 
       FIG. 7A  is a top plan view of a third exemplary mainframe provided in accordance with the present invention. 
       FIG. 7B  is a top plan view of a first alternative embodiment of the mainframe of  FIG. 7A  provided in accordance with the present invention. 
       FIG. 7C  is a top plan view of a second alternative embodiment of the mainframe of  FIG. 7A  provided in accordance with the present invention. 
       FIG. 8A  is a top plan view of an exemplary pass through chamber employing one or more spacers in accordance with the present invention. 
       FIG. 8B  is a top plan view of an exemplary extended pass through chamber provided in accordance with the present invention. 
       FIG. 9  is a top plan view of an exemplary load lock chamber provided in accordance with the present invention. 
   

   DETAILED DESCRIPTION 
   The present invention relates to extended mainframe designs that allow additional and/or larger chambers to be placed around a mainframe while maintaining service access to the mainframe, as well as to the process chambers and/or load lock chambers coupled to the mainframe. 
     FIG. 1  is a top plan view of a conventional vacuum mainframe  100  that may be employed during semiconductor device manufacturing. The vacuum mainframe  100  includes a central transfer chamber region  101  and a plurality of facets  102   a - f  each adapted to couple to a process chamber, load lock chamber, or other chamber (e.g., a preclean, bake-out, cool down, or metrology or defect detection chamber, or the like). While the mainframe  100  of  FIG. 1  is shown as having six facets, it will be understood that fewer or more facets may be provided. 
   During a typical application, a plurality of load lock chambers  104   a - b  are coupled to the mainframe  100 , such as at facets  102   e ,  102   f  as shown. A factory interface  106  may be coupled to the load lock chambers  104   a - b  and may receive substrate carriers  108   a - c  at load ports (not separately shown) of the factory interface  106 . A factory interface robot (not separately shown) within the factory interface  106  thereafter may obtain substrates from the substrate carriers  108   a - c  and transfer the substrates to the load lock chambers  104   a - b  (or transfer substrates from the load lock chambers  104   a - b  to the substrate carriers  108   a - c ). A mainframe robot  110  may transfer substrates between the load lock chambers  104   a - b  and any process or other chambers coupled to the mainframe  100  (e.g., at facets  102   a - d ) during semiconductor device manufacturing. 
     FIG. 2  is a top plan view of the mainframe  100  of  FIG. 1  showing four large chambers  200   a - d  coupled to the mainframe  100 . With reference to  FIGS. 1 and 2 , in the conventional mainframe  100 , a shorter reach is employed by the mainframe robot  110  for transferring substrates to and from the load lock chambers  104   a ,  104   b  than is used for transferring substrates to and from the process chambers  200   a - d  coupled to the mainframe  100  (as shown). 
   To increase clearance between the load lock chambers  104   a - b  and the process chambers  200   a - d  (e.g., for serviceability), the load lock chambers typically are rotated together (as shown). Nonetheless, serviceability issues may arise when large process chambers, such as etch chambers, chemical vapor deposition (CVD) chambers, atomic layer deposition (ALD) chambers, physical vapor deposition (PVD) chambers or the like, are employed with the mainframe  100 . For example, when four large process chambers are coupled to the mainframe  100  as shown in  FIG. 2 , the mainframe  100  and/or the load lock chambers  104   a - b  may become unserviceable, or service access may be limited and/or unsafe (e.g., less than the 24″ SEMI standard). Accordingly, only up to three large process chambers typically are employed with the mainframe  100 . 
     FIG. 3A  is a top plan view of a first exemplary mainframe  300  provided in accordance with the present invention. Compared to the conventional mainframe  100  of  FIGS. 1 and 2 , the mainframe  300  is “stretched” toward the factory interface  106  (as shown). The mainframe  300  may be stretched, for example, to the maximum reach of the mainframe robot  110  (or to any other suitable distance). In at least one embodiment, the mainframe  300  is stretched so that the extension of the mainframe robot  110  is increased by about 10 inches when transferring substrates to and from the load lock chambers  104   a - b  (compared to the extension of the mainframe robot  110  within the conventional mainframe  100 ). (As shown in  FIG. 3A , the mainframe  300  is stretched by increasing the length of facets  102   c ,  102   d  formed in a sidewall of the mainframe  300 , which may lead to a slight increase in the size of a central transfer region  301 ). 
   By stretching the mainframe  300 , four large chambers may be installed around the mainframe  300  and still serviced safely. For example,  FIG. 4  is a top plan view of the first exemplary mainframe  300  having four large process chambers  400   a - d  coupled to the mainframe  300 . Service access is improved and safe, even when full-sized chambers are employed. Servicing may be performed, for example, between the process chambers coupled to facet  102   c  or  102   d  and the factory interface  106 . In some embodiments, SEMI standard access requirements, such as 24″ or greater of access, may be provided. 
   By stretching the mainframe  300  by an amount that does not exceed the reach constraints of the mainframe robot  110 , no significant cost is incurred by modifying the mainframe  300 . For example, the same mainframe robot  110 , slit valves, load lock chambers, etc., used within the conventional mainframe  100  may be employed within the stretched mainframe  300 . 
   With reference to  FIG. 3B , in addition or as an alternative, greater service access may be achieved by placing a spacer  303   a  between the facet  102   e  and the load lock chamber  104   a  and/or a spacer  303   b  between the facet  102   f  and the load lock chamber  104   b  so as to create additional space between the process chambers  400   a  and/or  400   d  and the factory interface  106  ( FIG. 4 ). The spacers  303   a - b  may include, for example, tunnels or similar structures that extend between the mainframe  300  and the load lock chambers  104   a  and/or  104   b . Similar spacers  303   a - b  may be used between the load lock chambers  104   a  and/or  104   b  and the factory interface  106  as shown in  FIG. 3C  (e.g., about a 6″ to 8″ length sheet metal or similar tunnel). 
   The length of the body of the load lock chamber  104   a  and/or  104   b  additionally or alternatively may be increased so as to create additional space between the process chambers  400   a  and/or  400   d  and the factory interface  106 . The use of spacers and/or an extended load lock chamber body length may increase the distance between the mainframe  300  and the factory interface  106  and provide great service access. 
     FIG. 5A  is a top plan view of a second exemplary mainframe  500  provided in accordance with the present invention. Compared to the conventional mainframe  100  of  FIGS. 1 and 2 , a single facet  102   d  of the mainframe  500  (formed in a sidewall of the mainframe) is “stretched” toward the factory interface  106  (as shown). The facet  102   d  of the mainframe  500  may be stretched, for example, to the maximum reach of the mainframe robot  110  (or to any other suitable distance). In at least one embodiment, the facet  102   d  of the mainframe  500  is stretched so that the extension of the mainframe robot  110  is increased by about 10 inches when transferring substrates to and from a single load lock chamber  502  employed with the mainframe  500  (compared to the extension of the mainframe robot  110  within the conventional mainframe  100 ). Note that a central transfer region  504  of the mainframe  500  is not significantly increased in size over that of the conventional mainframe  100 . 
   By stretching only the facet  102   d  of the mainframe  500 , five large chambers may be installed around the mainframe  500  and still serviced safely. For example,  FIG. 6  is a top plan view of the second exemplary mainframe  500  having five large process chambers  600   a - e  coupled to the mainframe  500 . Service access is improved and safe, even when full-sized chambers are employed. Servicing may be performed, for example, between the process chamber coupled to facet  102   d  and the factory interface  106 . In some embodiments, SEMI standard access requirements, such as 24″ or greater of access, may be provided. 
   Note that the facet  102   c  alternatively may be stretched while the facet  102   d  remains unstretched. In such an embodiment, the load lock chamber  502  is coupled to the facet  102   e  and servicing may be performed, for example, between the process chamber coupled to facet  102   c  and the factory interface  106 . 
   By stretching a single facet of the mainframe  500  by an amount that does not exceed the reach constraints of the mainframe robot  110 , no significant cost is incurred by modifying the mainframe  500 . For example, the same mainframe robot  110 , slit valves, load lock chambers, etc., used within the conventional mainframe  100  may be employed within the stretched mainframe  500 . 
   As shown in  FIG. 5A , the load lock chamber  502  is rotated in a manner similar to the load lock chambers  104   a - b  of  FIG. 3A  (e.g., by about 5 to 10 degrees, although other degrees of rotation may be used). The mainframe  500  of  FIG. 5A  may be serviced even when five large (full-size) chambers are coupled to the mainframe  500 . The combination of a stretched mainframe and load lock chamber rotation increases serviceability. 
   As a further example, when all chambers are operated in parallel (e.g., perform the same process), the use of five chamber facets is 25% more productive than the use of four chamber facets. For a sequential process sequence, additional throughput improvement may be realized. For example, a typical metal etch process employs two etch chambers and two strip chambers. Each etch chamber generally has about two-thirds (⅔) of the throughput of a strip chamber (e.g., 20 wafers/hour for etch versus 30 wafers/hour for strip). By employing all five facets, an additional etch chamber may be coupled to the mainframe  500  so that three etch chambers and two strip chambers are present. The use of three etch chambers and two strip chambers leads to a 50% throughput improvement when compared to the use of two etch chambers and two strip chambers in other mainframe configurations. 
   In addition or as an alternative, greater service access may be achieved by placing a spacer  506  between the facet  102   f  and the load lock chamber  502  so as to create additional space between the process chamber  600   d  and the factory interface  106  ( FIG. 6 ). The spacer  506  may include, for example, a tunnel or similar structure that extends between the mainframe  500  and the load lock chamber  502 . A similar spacer may be used between the load lock chamber  502  and the factory interface  106  as shown in  FIG. 5C  (e.g., about a 6″ to 8″ length sheet metal or similar tunnel). 
   The length of the body of the load lock chamber  502  additionally or alternatively may be increased so as to create additional space between the process chamber  600   d  and the factory interface  106 . The use of spacers and/or an extended load lock chamber body length may increase the distance between the mainframe  500  and the factory interface  106  and provide great service access. 
     FIG. 7A  is a top plan view of a third exemplary mainframe  700  provided in accordance with the present invention. The third mainframe  700  includes a first mainframe section  702  (e.g., a high vacuum section) coupled to a second mainframe section  704  (e.g., a lower vacuum, input section). The first and second mainframe sections  702 ,  704  are coupled via pass through chambers  706   a - 706   b . The first mainframe section  702  includes facets  708   a - f  (formed in a first sidewall of the mainframe) and the second mainframe section  704  includes facets  710   a - f  (formed in a second sidewall of the mainframe). Each mainframe section  702 ,  704  includes a mainframe robot  712   a ,  712   b.    
   As shown in  FIG. 7A , the first mainframe section  702  is similar to the mainframe  300  of  FIGS. 3A-C  and  4 . That is, the facets  708   c  and  708   d  of the first mainframe section  702  are “stretched” toward the factory interface  106  (as shown). The facets  708   c ,  708   d  of the first mainframe section  702  may be stretched, for example, to the maximum reach of the first mainframe robot  712   a  (or to any other suitable distance). In at least one embodiment, the facets  708   c ,  708   d  of the first mainframe section  702  are stretched so that the reach of the first mainframe robot  712   a  is increased by about 10 inches when transferring substrates to and from the pass through chambers  706   a ,  706   b  (compared to the reach of a mainframe robot within a conventional mainframe). By stretching the first mainframe section  702  as described, four large chambers may be installed around the first mainframe section  702  and still serviced safely. 
   In the second mainframe section  704 , a single facet  710   d  of the mainframe section  704  is “stretched” toward the factory interface  106  (as shown). The facet  710   d  of the second mainframe section  704  may be stretched, for example, to the maximum reach of the second mainframe robot  712   b  (or to any other suitable distance). In at least one embodiment, the facet  710   d  of the second mainframe section  704  is stretched so that the extension of the mainframe robot  712   b  is increased by about 10 inches when transferring substrates to and from a single load lock chamber  502  employed with the mainframe  700  (compared to the extension of a mainframe robot within a conventional mainframe). By stretching only the facet  710   d  of the second mainframe section  704 , five large chambers may be installed around the second mainframe section  704  and still serviced safely. 
   Through use of the stretched mainframe sections  702 ,  704 , the mainframe  700  may provide a total of seven facets for large, full-sized chambers. A central transfer region  714  of the first mainframe section  702  is slightly larger than a central transfer region  716  of the second mainframe section  704 . 
   In addition or as an alternative, greater service access may be achieved by placing a spacer  720  ( FIG. 7B ) between the facet  710   f  and the load lock chamber  502  so as to create additional space between any process chamber coupled to facet  710   d  and the factory interface  106 . The spacer  720  may include, for example, a tunnel or similar structure that extends between the second mainframe section  704  and the load lock chamber  502 . A similar spacer  720  may be used between the load lock chamber  502  and the factory interface  106  as shown in  FIG. 7C  (e.g., about a 6″ to 8″ length sheet metal or similar tunnel). 
   In addition or as an alternative, greater service access may be achieved by placing a spacer between the facet  708   e  and the pass through chamber  706   a  and/or a spacer between the facet  708   f  and the pass through chamber  706   b  so as to create additional space between the pass through chambers  706   a ,  706   b  and process chambers coupled to facets  708   c ,  708   d  ( FIG. 7A ). The spacers may include, for example, tunnels or similar structures that extend between the first mainframe section  702  and the pass through chambers  706   a ,  706   b . Spacers also may be used between the pass through chambers  706   a ,  706   b  and the second mainframe section  704 . 
     FIG. 8A  is a top plan view of an exemplary embodiment of the first pass through chamber  706   a  having a first spacer  802   a  and a second spacer  802   b  coupled thereto in accordance with the present invention. The second pass through chamber  706   b  may be similarly configured. 
   The length of the body of the pass through chambers  706   a  and/or  706   b  additionally or alternatively may be increased. For example,  FIG. 8B  is an exemplary embodiment of the second pass through chamber  706   b  having a body region  804  extended in accordance with the present invention. Other body portions may be extended. The first pass through chamber  706   a  may be similarly configured. 
   The length of the body of the load lock chamber  502  additionally or alternatively may be increased so as to create additional space between any process chamber coupled to facet  710   d  and the factory interface  106 . For example,  FIG. 9  illustrates an exemplary embodiment of the load lock chamber  502  having a body region  902  extended in accordance with the present invention. Other body portions may be extended. The load lock chambers  104   a - b  may be similarly extended. The use of spacers and/or an extended load lock chamber body length may increase the distance between the mainframe  700  (or  500 ) and the factory interface  106  and provide great service access. 
   The foregoing description discloses only exemplary embodiments of the invention. Modifications of the above disclosed apparatus and methods which fall within the scope of the invention will be readily apparent to those of ordinary skill in the art. For instance, the mainframes  300 ,  500  and/or the mainframe sections  702 ,  704  may include more or fewer than six facets. Accordingly, while the present invention has been disclosed in connection with exemplary 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.