Abstract:
The invention provides a fluid delivery system, including a mounting structure, a plurality of rows of locator alignment components secured to the mounting structure, a plurality of rows of fluid connecting pieces, each having inlet and outlet ports and a fluid communication passage interconnecting the ports, the fluid connecting pieces being arranged in pairs, each pair including two of the fluid connecting pieces located next to one another in a respective row of fluid connecting components, the fluid connecting pieces of each pair being releasably held by and aligned relative to one another by a respective one of the locator alignment components, and a plurality of manifold pieces extending transverse to the rows of fluid connecting pieces, at least one manifold piece having a manifold passage with a center line crossing over a center line interconnecting the farthest ports of one of the pairs and being removable without removing the locator alignment component by which the respective pair is held from the mounting structure.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     The present patent application claims priority from provisional patent application No. 60/458,115, filed on Mar. 26, 2003, which is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1). Field of the Invention  
         [0003]     This invention relates to a fluid delivery system, or fluid delivery system, of the kind that may include interconnected fluid control components such as valves, regulators, mass flow controllers, filters, and pressure transducers.  
         [0004]     2). Discussion of Related Art  
         [0005]     Fluid delivery systems, also known as fluid delivery systems, are used in, for example, semiconductor processing systems to provide predetermined gases or mixtures of gases at predetermined flow rates and predetermined pressures into a processing chamber. Various supply gases are connected to inlets of such a manifold, and one or more outlets of the manifold are connected to the processing chamber. Such a manifold system usually includes components such as valves, regulators, mass flow controllers, filters, and pressure transducers that are connected to one another over a two-dimensional area in a manner that will ensure delivery of the desired gases or mixtures of gases at the desired flow rates and pressures to the processing chamber.  
         [0006]     Fluid delivery systems are frequently in the form of smaller components that can be mounted to a base mounting structure in a modular fashion to create a desired flow pattern between fluid control components. It has been found that maintenance to such systems is usually extremely cumbersome because the replacement of a single piece may require disassembly and reassembly of a large number of pieces, and usually involves the breaking of a large number of seals that are expensive to replace.  
       SUMMARY OF THE INVENTION  
       [0007]     The invention provides a fluid delivery system, including a mounting structure, a plurality of rows of locator alignment components secured to the mounting structure, a plurality of rows of fluid connecting pieces, each having inlet and outlet ports and a fluid communication passage interconnecting the ports, the fluid connecting pieces being arranged in pairs, each pair including two of the fluid connecting pieces located next to one another in a respective row of fluid connecting components, the fluid connecting pieces of each pair being releasably held by and aligned relative to one another by a respective one of the locator alignment components, and a plurality of manifold pieces extending transverse to the rows of fluid connecting pieces, at least one manifold piece having a manifold passage with a center line crossing over a center line interconnecting the farthest ports of one of the pairs and being removable without removing the locator alignment component by which the respective pair is held from the mounting structure.  
         [0008]     The locator alignment components may be arranged in sets, each set including two of the locator alignment components next to one another in a respective row of locator alignment components, and each fluid connecting piece being held by both locator alignment components in a respective set.  
         [0009]     A gap may be defined between fluid connecting pieces of a respective pair, the manifold piece being removable out of the gap without removal of the pair from the locator alignment component holding the pair.  
         [0010]     The system may further include a plurality of locator alignment fasteners removably fastening the locator alignment pieces to the mounting structure.  
         [0011]     The locator alignment components may, for example, be cradles. Each cradle may prevent movement of the fluid connecting pieces of a respective pair in x, y, and θ.  
         [0012]     The system may further include a plurality of fluid control components placed in flow communication with one another through the fluid communication passages and the manifold passages.  
         [0013]     One of the fluid control components may have an inlet passage connected to an outlet port of one of the connecting pieces of a pair, and an outlet passage connected to an inlet port of another one of the connecting pieces of the respective pair.  
         [0014]     The fluid control components may include at least one of a valve, a regulator, a mass flow controller, a filter, and a pressure transducer.  
         [0015]     The ports of each respective fluid connecting piece may be located into the same side of the respective fluid connecting piece.  
         [0016]     The system may further include at least one fluid T-piece having at least three ports and at least one fluid communication passage interconnecting all three ports, the T-piece being releasably held and aligned relative to one of the locator alignment components, one of the ports of the fluid T-piece being connected to the manifold piece.  
         [0017]     The system may further include at least one fluid elbow piece having at least two ports and at least one fluid communication passage interconnecting both ports, the elbow piece being releasably held and aligned relative to one of the locator alignment components, one of the ports of the fluid elbow piece being connected to the manifold piece.  
         [0018]     A gap may be defined between the fluid connecting pieces of a respective pair, and the system may further include a purge piece between the fluid connecting pieces of the respective pair, having at least two ports, one of which is connected to the manifold piece.  
         [0019]     The system may further include a locator end piece holding and aligning one of the fluid connecting components and being smaller than the locator alignment components.  
         [0020]     The invention also provides a fluid delivery system, including a mounting structure, at least three locator components secured to the mounting structure, at least three pairs of fluid connecting pieces, each having inlet and outlet ports and a fluid communication passage interconnecting the ports, each respective pair being releasably held and aligned by a respective one of the locator pieces, and a plurality of manifold pieces having a manifold passage having a center line crossing over a line interconnecting the two farthest ports of the fluid connecting pieces and being removable without removing any of the three locator components.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0021]     The invention is further described by way of example with reference to the accompanying drawings, wherein:  
         [0022]      FIG. 1  is a perspective view of one row of components of a fluid delivery system, according to an embodiment of the invention;  
         [0023]      FIG. 2  is a perspective view of one of many locator alignment cradles forming part of the system;  
         [0024]      FIG. 3  is a perspective view of one of many fluid connecting blocks forming part of the system;  
         [0025]      FIG. 4  is a perspective view of additional components of the system that are used to interconnect rows extending in an x-direction to one another in a y-direction;  
         [0026]      FIG. 5  is a perspective view of a fluid T-piece forming part of the system;  
         [0027]      FIG. 6  is a perspective view of a purge piece forming part of the system;  
         [0028]      FIG. 7  is a perspective view of a locator end piece forming part of the system;  
         [0029]      FIG. 8  is a perspective view of a fluid T-piece that may be used instead of the T-piece of  FIG. 5 ;  
         [0030]      FIG. 9  is a perspective view of another fluid T-piece that may be used instead of the fluid T-piece of  FIG. 5 ;  
         [0031]      FIG. 10  is a perspective view of a purge piece that may be used instead of the purge piece of  FIG. 6 ;  
         [0032]      FIG. 11  is a perspective view of a flange piece forming part of the system;  
         [0033]      FIG. 12  is a perspective view of a flange component that may be used together with the flange piece of  FIG. 11 ;  
         [0034]      FIG. 13  is a perspective view of an elbow piece that can be used at an end of a row of fluid connecting blocks;  
         [0035]      FIG. 14  is a perspective view of an elbow piece that may be used instead of the elbow piece of  FIG. 13 ;  
         [0036]      FIG. 15  is a perspective view of an elbow piece that may be used instead of the elbow piece of  FIG. 13 ;  
         [0037]      FIG. 16  is a perspective view of further components of the system, particularly illustrating the positioning of the locator end pieces of  FIG. 7 ; and  
         [0038]      FIG. 17  is a perspective view of the system as fully assembled.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0039]      FIG. 1  of the accompanying drawings illustrates one row of a fluid delivery, or gas manifold, system  10  according to an embodiment of the invention, including a base mounting plate  12 , three locator alignment cradles  14 , six locator fastener screws  16 , three fluid connecting blocks  18 , six seals  20 , three fluid control components  22 , and twelve component fastener screws  24 .  
         [0040]     The base mounting plate  12  has six cradle mounting openings  26  formed therein. Six nuts  28  are welded to a bottom surface of base mounting plate  12 . Each nut  28  has a threaded hole which is aligned with a respective one of the cradle mounting openings  26 .  
         [0041]     Referring to  FIG. 2 , each locator alignment cradle  14  has a base portion  30  and four securing and alignment pillars  32 . The alignment pillars  32  extend upward from four corners of the base portion by a distance  34 , are spaced from one another in an x-direction by a distance  36 , and in a y-direction by a distance  38 . Two base plate mounting openings  40  are formed in the base portion  30 . Six connecting block alignment openings  42  are also formed in the base portion  30 . A respective threaded component mounting opening  44  is formed into an upper surface of each respective alignment pillar  32 .  
         [0042]     Referring again to  FIG. 1 , the locator alignment cradles  14  are positioned in a row extending in an x-direction on the base mounting plate  12 , with each base plate mounting opening  40  aligned with a respective one of the cradle mounting openings  26 .  
         [0043]     A respective one of the locator fastener screws  16  is subsequently inserted into each respective one of the base plate mounting openings  40 , a cradle mounting opening  26 , and then is screwed into one of the nuts  28 . The locator alignment cradles  14  are thereby secured to the base mounting plate  12 . Although there should be little need to remove the locator alignment cradles  14  for maintenance purposes, the locator alignment cradles  14  can still be removed by undoing the locator fastener screws  16 , for example for purposes of removing some of the locator alignment cradles  14  or rearranging the locator alignment cradles  14  in a modular fashion.  
         [0044]     Referring to  FIG. 3 , one of the fluid connecting blocks  18  has a height  48  in a z-direction, a length  50  in an x-direction, and a width  52  in a y-direction. Inlet and outlet ports  54  are formed in an upper surface  56  of the fluid connecting block  18 . A passage  60  is drilled into an end surface  62  and interconnects lower portions of the ports  54 . The passage  60  is closed off at the surface  62 . A fluid connecting passage is thereby jointly defined by lower portions of openings forming the ports  54  and the passage  60 . A gas can thus flow into one of the ports  54 , through the fluid connecting block  18 , and exit through the other port  54 . Four cradle alignment pins  64  stand proud of a lower surface of the fluid connecting block  18 .  
         [0045]     Referring again to  FIG. 1 , the fluid connecting blocks  18  are inserted into the locator alignment cradles  14 . The fluid connecting block  18  to the left has a left portion which is located on the locator alignment cradle  14  to the left, and a right portion which is located on the locator alignment cradle  14  in the middle. The fluid connecting block  18  in the middle is held jointly by the locator alignment cradles  14  in the middle and to the right. The width ( 52  in  FIG. 3 ) of each fluid connecting block  18  matches the distance in a y-direction ( 38  in  FIG. 2 ) and defined by the locator alignment cradles  14  so that the fluid connecting blocks  18  are prevented from movement in a y-direction and in θ in an x-y plane about a z-axis. The cradle alignment pins ( 64  in  FIG. 3 ) also engage with the connecting block alignment openings ( 42  in  FIG. 2 ) to further prevent movement of the fluid connecting blocks  18  in a y-direction and in θ. Interengagement of the cradle alignment pins  64  with the connecting block alignment openings  42  also prevent sliding of the fluid connecting blocks  18  in an x-direction relatively toward or away from one another, so that a gap  68  is maintained between adjacent ones of the fluid connecting blocks  18 . The fluid connecting blocks  18  are thus positioned relative to one another with their ports aligned in a row  70  extending in an x-direction and with gaps  68  defined between them.  
         [0046]      FIG. 4  illustrates additional components of the fluid delivery system  10 , including additional locator alignment cradles  14  and additional fluid connecting blocks  18 . The additional locator alignment cradles  14  and fluid connecting blocks  18  are mounted, as illustrated in  FIG. 1 , in rows that extend in an x-direction but are located adjacent one another in a y-direction.  
         [0047]     The fluid delivery system  10  further includes a fluid T-piece  74 , a manifold piece  76 , and a purge piece  78 .  
         [0048]     Referring to  FIG. 5 , the fluid T-piece  74  has a length  80  in an x-direction which equals the length  50  of the fluid connecting block  18  in  FIG. 3  plus the length of the gap  68  in  FIG. 1 . In addition to inlet and outlet ports  54 , the fluid T-piece  74  also has a third port  82  extending in a y-direction. The third port  82  is in flow communication with both of the inlet and outlet ports  54  of the fluid T-piece  74 . Gases can, for example, flow in a downward z-direction into the inlet and outlet ports  54 , be combined within the fluid T-piece  74 , and flow in a y-direction out of the third port  82 .  
         [0049]     Referring again to  FIG. 4 , the manifold piece  76  is connected to the third port  82  and extends in a y-direction away from the fluid T-piece  74 . Referring to  FIG. 6 , the purge piece  78  has one port  54  in an upper surface thereof, and an additional port  84  extending therefrom in a y-direction. The ports  54  and  84  of the purge piece  78  are in flow communication with one another, so that a gas can, for example, flow in a y-direction into the additional port  84  and leave in a z-direction out of the port  54  of the purge piece  78 . The purge piece  78  has a width  88  that substantially equals the gap  68  in  FIG. 1 . Referring again to  FIG. 4 , the additional port  84  of the purge piece  78  is connected to the manifold piece  76 .  
         [0050]     The fluid T-piece  74 , together with the manifold piece  76  and the purge piece  78 , can be inserted downward into the locator alignment cradles  14 . The fluid T-piece  74  fits on two of the cradles  14  in the same manner as one of the fluid connecting blocks  18 , except that the fluid T-piece  74  extends further to the left over its cradle  14  than one of the fluid connecting blocks  18 . The manifold piece  76  extends through the gaps ( 68  in  FIG. 1 ). The manifold piece  76  has a center line that, when viewed from the top, crosses over a center one of the rows  70 . The purge piece  78  is inserted into a gap between two of the fluid connecting blocks  18 . The inlet and outlet ports  54  of the fluid T-piece  74  are located in one of the rows  70 , and the port  54  of the purge piece  78  is located in another one of the rows  70 .  
         [0051]     Referring again to  FIG. 1 , a seal  20  is located on each one of the ports  54 , whereafter the fluid control components  22  are positioned over the fluid connecting blocks  18 . Each fluid control component  22  has a respective flange  90  with four cradle mounting openings  92  therein. The cradle mounting openings  92  of each component  22  are located over the component mounting openings  44  of a respective locator alignment cradle  14 . A respective component fastener screw  24  is inserted through a respective cradle mounting opening  92  and screwed into a component mounting opening  44  to secure the respective fluid control component  22  to the respective locator alignment cradle  14  and compress two of the seals  20 . As with the locator alignment cradles  14 , the fluid control components  22  are located in a row. Adjacent ones of the fluid control components  22  are in flow communication with one another through a respective one of the fluid connecting blocks. It can thus be seen that the fluid control components  22  located in a row extending in an x-direction can be placed in flow communication with one another utilizing the components illustrated in  FIG. 1 . Referring again to  FIG. 4 , the fluid T-piece  74 , the manifold piece  76 , and the purge piece  78  can be used to place fluid control components that are in different rows spaced from one another in a y-direction in flow communication with one another.  
         [0052]     An advantage of the invention is that the fluid delivery system  10  is easily maintained. The manifold piece  76  can, for example, be replaced by simply removing any fluid control pieces located over the manifold piece  76  and then lifting the manifold piece  76  together with the fluid T-piece  74  and the purge piece  78  out of the locator alignment cradles  14 . There is thus no need to remove any of the locator alignment cradles  14  or any of the fluid connecting blocks  18  in order to replace the manifold piece  76 , even though a center line of the manifold piece  76  crosses over one of the rows  70 .  
         [0053]      FIGS. 7 through 15  illustrate further components that may be used for constructing the fluid delivery system  10  and are presented for purposes of completeness.  FIG. 7  illustrates a locator end piece  96  having only two pillars  98 . The locator end piece  96  has a length  100  in an x-direction which is less than a length  102  of the locator alignment cradle  14  in an x-direction. As illustrated in  FIG. 16 , the locator end pieces  96  may, for example, be used adjacent ends of a row of locator alignment cradles  14 , but do not have the additional pillars of the locator alignment cradles  14  in order to save space in an x-direction.  
         [0054]      FIG. 9  illustrates a fluid T-piece  106  which is the same as the fluid T-piece  74  of  FIG. 5 , except that a third port  108  thereof extends in an opposite direction than the third port  82 .  FIG. 8  illustrates a fluid T-piece  110  which is the same as the fluid T-piece  74  of  FIG. 5 , except that the fluid T-piece  110  has third and fourth ports  112  and  114  extending in opposite directions. The combination of the fluid T-pieces of  FIGS. 5, 8 , and  9  allow for a modular design wherein gas can be directed up, down, or in both directions on a y-axis.  
         [0055]      FIG. 10  illustrates a purge piece  120  which is the same as the purge piece  78  of  FIG. 6  except that, in addition to the ports  54  and  84  of the purge piece  78  of  FIG. 6 , an additional port  116  is provided, which extends in an opposite direction as the port  84 . The purge piece  120  thus allows for flow both upward and downward thereof on a y-axis.  
         [0056]      FIG. 11  illustrates a flange piece  122  that can be used for changing flow between a z-direction and an x-direction, and would typically be located at an end of a row.  FIG. 12  illustrates a flange connection  124  that may be used in combination with the flange connection piece  122  of  FIG. 11  to direct flow in an x-direction, for example for purposes of connection to an external source of gas.  
         [0057]     FIGS.  13  to  15  illustrate elbow pieces  130 ,  132 , and  134  respectively. The elbow pieces  130 ,  132 , and  134  are typically located at an end of a particular row. Each elbow piece  130 ,  132 , and  134  has a single port  54  in an upper surface thereof, so that flow in an x-direction is terminated. Ports  136  allow for flow in a y-direction into or out of the elbow pieces  130 ,  132 , or  134 .  
         [0058]      FIGS. 16 and 17  illustrate final assembly of the fluid delivery system  10 . When fully assembled, as shown in  FIG. 17 , the fluid delivery system  10  includes various flow fluid control components  22  connected to one another in an x- and y-array, including regulators, mass flow controllers, filters, and pressure transducers.  
         [0059]     Other embodiments of the invention may also be used to flow fluids other than gases, such as liquids. The components of the fluid delivery system may be sized and shaped differently to accommodate different designs of fluid control components utilizing different sealing interfaces. A complete fluid delivery system need not include the manifold pieces and comprise a row of locator alignment cradles, fluid connecting pieces, and fluid control components.  
         [0060]     While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative and not restrictive of the current invention, and that this invention is not restricted to the specific constructions and arrangements shown and described since modifications may occur to those ordinarily skilled in the art.