Abstract:
The invention provides apparatus and manufacturing methods for a liner adapted to enclose a space within a substrate carrier and further adapted to prevent gas from reaching the enclosed space. The liner may be removable from the substrate carrier. The liner may be self-supporting and/or the liner may be supported by interior walls of the substrate carrier. The liner may be adapted to absorb particles to prevent contamination of substrates stored in the substrate carrier. The liner may be an interior glass coating in a substrate carrier that prevents outgassing from the substrate carrier. Numerous other aspects are disclosed.

Description:
RELATED APPLICATIONS 
       [0001]    The present application claims priority to U.S. Provisional Patent Application Ser. No. 60/751,105, filed on Dec. 16, 2005 and entitled “SUBSTRATE CARRIER HAVING AN INTERIOR LINING,” which is hereby incorporated by reference herein for all purposes. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to electronic device manufacturing and, more particularly, to a substrate carrier having an interior lining. 
       BACKGROUND 
       [0003]    It is generally preferable to protect substrates (e.g., patterned or unpatterned semiconductor wafers, glass panels, polymer substrates, reticules, masks, glass plates or the like) from exposure to any potential contaminating particles. Thus, such substrates may be stored in air tight containers. However, the substrates must typically be transported to different process tools within an electronic device manufacturing facility. Conventional substrate carriers may not provide air tight compartments. Thus, what is needed are methods and apparatus for transporting substrates in sealable containers as well as systems and methods for accessing the substrates without exposing the substrates to potential contaminating particles. 
       SUMMARY OF THE INVENTION 
       [0004]    In some aspects, the present invention provides a substrate carrier that includes a substrate carrier body, wherein the substrate carrier body defines an interior region bounded by an inner top wall, an inner bottom wall and a plurality of inner side walls; a substrate carrier door coupled to the substrate carrier body, wherein the substrate carrier door has an inner wall which further defines the interior region; and a lining along at least a portion of the inner walls of the substrate carrier body and the inner wall of the substrate carrier door adapted to prevent permeation of a gas into and out of the interior region of the substrate carrier. 
         [0005]    In other aspects, the present invention provides a substrate carrier lining that includes a top portion adapted to be positioned along an inner top wall of the substrate carrier defined by a substrate carrier body; a bottom portion adapted to be positioned along a bottom wall of the substrate carrier defined by the substrate carrier body; a plurality of side portions adapted to be positioned along corresponding inner side walls of the substrate carrier defined by the substrate carrier body; and an additional portion adapted to be positioned along an inner wall of a door of the substrate carrier. The portions of the lining may be adapted to prevent permeation of a gas into and out of the interior region of the substrate carrier. 
         [0006]    In yet other aspects, the present invention provides a method of manufacturing a substrate carrier that includes forming a substrate carrier body, wherein the substrate carrier body defines an interior region bounded by an inner top wall, an inner bottom wall and a plurality of inner side walls; forming a substrate carrier door, wherein the substrate carrier door has an inner wall which further defines the interior region; and forming a lining along at least a portion of the inner walls of the substrate carrier body and the inner wall of the substrate carrier door. The lining may be adapted to prevent permeation of a gas into and out of the interior region of the substrate carrier. 
         [0007]    In still other aspects, the present invention provides an apparatus that includes a substrate carrier and a liner adapted to enclose a space within the substrate carrier and further adapted to prevent gas from reaching the enclosed space. The liner may be removable from the substrate carrier. The liner may be self-supporting and/or the liner may be supported by interior walls of the substrate carrier. The liner may be adapted to absorb particles to prevent contamination of substrates stored in the substrate carrier. 
         [0008]    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 
         [0009]      FIG. 1  is a side-cross-sectional view of an exemplary substrate carrier in accordance with an embodiment of the present invention. 
           [0010]      FIG. 2  is a side-cross-sectional view of a second exemplary substrate carrier in accordance with an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0011]    The present invention relates to electronic device manufacturing and, more particularly, to a substrate carrier, such as a front opening unified pod (FOUP) or the like, having an interior lining. The substrate carrier may be used to house and transport one or more substrates such as patterned or unpatterned semiconductor wafers, glass panels, polymer substrates, reticules, masks, glass plates or the like. 
         [0012]    In accordance with the present invention, a substrate carrier is provided that has an interior lining. As used herein, the term “lining” includes a lining, a liner, a coating, or the like, whether self-supporting, insertable/removable, free-standing, one piece or multiple piece construction, mounted to the interior walls of the carrier, and/or applied to the interior walls of the carrier. In other words, the lining may be located on one or more interior walls of the substrate carrier or may be a separate structure for insertion into the substrate carrier. The lining may serve to prevent the outgassing, or the permeation of, a gas and/or the transport of particulates from the substrate carrier&#39;s interior region, through the walls of the substrate carrier, and into the environment surroundings of the substrate carrier. The interior lining may also serve to prevent contamination of the substrate carrier&#39;s interior region, and any substrates located within the substrate carrier, which may result from gas or contaminants entering the substrate carrier&#39;s interior from the substrate carrier walls and/or the environment that surrounds the substrate carrier. 
         [0013]    In an exemplary embodiment, the lining may be a sheet or a material which is placed on, coupled to, or formed on, the inner walls and/or interior components of the substrate carrier. For example, the lining may be a gas impermeable material such as a glass sheet, a glass coating or the like. In another exemplary embodiment, the lining may be a dielectric material such as silicon nitride, silicon dioxide, etc., or any other sheet, material or substance which prevents or substantially prevents the permeation of a gas and/or transport of particulates through a wall of the substrate carrier. 
         [0014]    In another exemplary embodiment, the lining may be an absorption barrier that absorbs a gas and/or particulates, while, at the same time, preventing their permeation through the same. Examples of absorption materials include desiccant materials or desiccant-like materials that have an affinity for particular gasses/vapors. A desiccant material may be, for example, “preconditioned” as the selective desiccant loads up with material. A replaceable lining additionally or alternatively may be used. In general, the lining may be reconditioned, reapplied and/or replaced. 
         [0015]    The substrate carrier of the present invention may be capable of holding and/or transporting any number of substrates. In this regard, the inventive substrate carrier may hold and/or transport a single substrate or a plurality of substrates. 
         [0016]      FIG. 1  is a side cross-sectional view of an exemplary substrate carrier of the present invention which is designated generally by the reference numeral  100 . With reference to  FIG. 1 , the substrate carrier  100  includes a substrate carrier body  102  having and defining an interior region  104 . The interior region  104  may be bounded by and defined by a top interior wall  106 , interior side walls  108  and an interior bottom wall  110 . The substrate carrier  100  may also contain substrates, or devices for holding or supporting the same, designated generally by the reference numeral  112 . In an exemplary embodiment, the substrate carrier  100  may be equipped or adapted to hold and/or transport any number of substrates. With reference once again to  FIG. 1 , the substrate carrier  100  also includes a substrate carrier door  114 , as shown. 
         [0017]    In the exemplary embodiment of  FIG. 1 , the substrate carrier  100  includes a lining  116  on the interior top wall  106 , each of the interior side walls  108  and the interior bottom wall  110 , as shown. The lining  116  may be placed on, located along, or formed on or along all or a portion of a wall or walls, including any corner regions. Likewise, the lining  116  may be placed on, located along, or formed on or along a component of the substrate carrier located adjacent to a respective wall or walls. 
         [0018]    The lining  116  also may be placed on, located along, or formed on or along all or a portion of the interior side of the substrate carrier door  114  or a component attached to the interior side of the substrate carrier door  114 . 
         [0019]    The lining  116  may be a gas impermeable material such as a glass sheet or a glass coating. In another exemplary embodiment, the lining  116  may be a silicon nitride sheet or coating, a silicon dioxide sheet or coating, or another dielectric material. In general, the lining  116  may be any suitable material or coating which may protect against outgassing and/or which may serve as a protective barrier to prevent the permeation of a gas and/or particulates into and/or from the interior region  104  of the substrate carrier  100 . 
         [0020]    The lining  116  may also be, and may serve as, an absorption barrier that absorbs a gas and/or particulates so as to prevent their permeation through the same. Exemplary absorptive materials suitable for the lining  116  include desiccant or desiccant-like materials, or the like. In this manner, the permeation of a gas or particulates into and/or from the inner region  104  of the substrate carrier  100  may be prevented or, at the very least, substantially minimized. 
         [0021]    The lining  116  may have any thickness sufficient to achieve substantial minimization of gas and/or particulate permeability. In an exemplary embodiment, the lining  116  may have a thickness ranging from about 1 micron to about 50 microns, although other thicknesses may be used, as may non-uniform and/or varying thicknesses. 
         [0022]    The lining  116  may be applied in any appropriate manner to the interior walls of the substrate carrier body  102  and the substrate carrier door  114 . The lining  116  may, for example, be a sheet material which may be placed on, glued onto, or otherwise coupled to the respective interior walls or components of the substrate carrier  100  (including the door  114 ). Alternatively, the lining  116  may be applied by spray coating, by covering the interior walls or components with a liquid coating which may dry as a solid sheet of material or by any other suitable technique. In another exemplary embodiment, the lining  116  may be vapor deposited onto the respective inner walls or components of the substrate carrier  100 . In general, the lining  116  may be applied or installed in any appropriate form (e.g., solid, liquid, gas, etc.) and/or in any appropriate manner. 
         [0023]    The lining  116  may serve to prevent any gas or particulates from permeating from the interior region  104  of the substrate carrier  100 , to and/or through the respective walls  106 ,  108  and  110  and/or the substrate carrier door  114 , and into the environment surrounding the substrate carrier  100 . The lining  116  may also serve to prevent contaminants from passing from the environment surrounding the substrate carrier  100  or from the components of the substrate carrier itself into the substrate carrier&#39;s interior region  104 . 
         [0024]    Although  FIG. 1  shows an exemplary substrate carrier adapted to hold a plurality of substrates, in another exemplary embodiment, the inventive substrate carrier may be designed or adapted to hold only a single substrate, or a few substrates, as shown in  FIG. 2 . 
         [0025]      FIG. 2  is a side cross-sectional view of another exemplary substrate carrier provided in accordance with the present invention which is designated generally by the reference numeral  200 . With reference to  FIG. 2 , the substrate carrier  200  includes a substrate carrier body  202  having an interior region  204 . The interior region  204  is bounded by a top interior wall  206 , interior side walls  208  and an interior bottom wall  210 . 
         [0026]    The substrate carrier  200  also includes a substrate carrier door  212  and a substrate support device  214 , which, in an exemplary embodiment, may be situated on, or attached to, the interior bottom wall  210 . 
         [0027]    The substrate carrier  200  also includes a lining  216  on the interior top wall  206 , each of the interior side walls  208  and the interior bottom wall  210 , as shown. 
         [0028]    In the exemplary embodiment of  FIG. 2 , the lining  216  may be placed on or along, located on, or formed on or along all or a portion of a wall or walls or other interior component, including any corner regions, of the substrate carrier  200 . For example, the support device  214 , or a portion of the same, may include the lining  216 . 
         [0029]    The substrate carrier  200  also may include the lining  216  on all or a portion of the interior side of the substrate carrier door  212 . 
         [0030]    The lining  216  may be a gas impermeable material such as a glass sheet or a glass coating. In another exemplary embodiment, the lining  216  may be a silicon nitride sheet or coating, a silicon dioxide sheet or coating, or another dielectric material. In general, the lining  216  may be any suitable material or coating which may protect against outgassing and/or which may serve as a protective barrier to prevent the permeation of a gas and/or particulates into and/or from the interior region  204  of the substrate carrier  200 . 
         [0031]    The lining  216  may also be, and may serve as, an absorption barrier that absorbs a gas and/or particulates so as to prevent their permeation through the same. Exemplary absorptive materials suitable for the lining  216  include desiccant or desiccant-like materials or the like. In this manner, the permeation of a gas or particulates into and/or from the inner region  204  of the substrate carrier  200  may be prevented or, at the very least, substantially minimized. 
         [0032]    The lining  216  of  FIG. 2 , like the lining  116  of  FIG. 1 , may have any desired thickness. In one embodiment, the lining  216  may have a thickness ranging from about 1 micron to about 50 microns. Also, like the lining  116  of  FIG. 1 , the lining  216  may be applied in any appropriate manner in a solid, liquid or gas phase. 
         [0033]    The lining  216  may serve to prevent any gas and/or particulates from permeating into or from the interior region  204  of the substrate carrier  200 , to and/or through the respective walls  206 ,  208  and  210  and/or the substrate carrier door  212 . 
         [0034]    In some embodiments, the lining  116 ,  216  may serve to prevent the material used to form the body or shell of the substrate carrier  100 ,  200  and/or the door  114 ,  212  itself from outgassing and contaminating a substrate stored in the substrate carrier  100 ,  200 . Additionally, the lining  116 ,  216  may act as a protective lining to prevent, for example, reactive species emitted or outgassed from a substrate from attacking the substrate carrier material. The lining  116 ,  216  may also allow the methods and/or materials with which substrate carriers are constructed to be altered. For example, a less costly and/or more easily manufacturable material may be used for the substrate carriers than would otherwise be unacceptable without the lining (e.g., the lining may provide the necessary barrier or isolation between the substrate(s) and the substrate carrier material). 
         [0035]    While the present invention has been described and illustrated in various exemplary embodiments, such descriptions are merely illustrative of the present invention and are not to be construed to be limitations thereof. In this regard, the present invention encompasses any and all modifications, variations and/or alternate embodiments within the scope of the present invention being limited only by the claims which follow.