Patent Publication Number: US-2003230700-A1

Title: Adjustable support member for manufacturing tool and other equipment

Description:
CLAIM TO DOMESTIC PRIORITY  
     [0001] The present non-provisional patent application claims priority to provisional application serial No. 60/388,681, entitled “Quad-Pod,” and filed on Jun. 13, 2002, by Zoltan A. Kemeny. 
    
    
     
       FIELD OF THE INVENTION  
       [0002] The present invention relates, in general, to equipment support members and, more particularly, to an adjustable support member for manufacturing tools and other equipment.  
       BACKGROUND OF THE INVENTION  
       [0003] Semiconductor devices are commonly used in the construction of electronic circuits for many types of electronic and consumer products. Integrated circuits and semiconductor devices are manufactured in specially constructed factories using highly customized and proprietary equipment and processes. The small nature of the individual semiconductor components comprising most integrated circuits, the demand for high reliability, and their susceptibility to contamination mandate the use of clean rooms and special manufacturing tools.  
       [0004] The tools and equipment used in the manufacture of semiconductors can generally be placed in one of two categories: tools that generate vibration and tools that receive vibrations. Examples of vibration-generating tools include chemical mechanical polishers (CMP) and other rotating or oscillating machinery. Examples of tools that are susceptible to vibration include optical devices such as burning tools and etchers, scanning electronic microscopes, and inspection tools.  
       [0005] Semiconductor clean rooms are typically configured with a raised floor constructed with a number of rectangular panels or plates suspended over a concrete base, slab on grade, or other solid foundation. The raised floor provides access to electrical conduits, wiring, piping, ventilation, duct works, and drainage running along and around the foundation. The semiconductor manufacturing tools and other equipment found in clean rooms must be mounted to a table, base plate, stand, or other assembly to support the mass of the tool in a stable and secure manner above the access floor, and to minimize the transfer of any vibrations between sets of equipment. If any vibration originating from rotating machinery should be transferred to vibration-sensitive equipment, then the manufacturing process being performed by such vibration-sensitive equipment could be impaired. For example, many optical burners or etchers are high precision tools operating in the nanometer range. Any vibration in the equipment can cause jitter or blur the optical focus and create defects in the integrated circuits.  
       [0006] Manufacturing tools are often mounted to tables or plates which are in turn supported by rigid pedestals or “elephant legs”, which are short-stands located under each corner or support area of the tool table. The raised flooring is arranged around the equipment support members. An example of a prior art pedestal is shown in FIG. 1. A manufacturing tool  10 , such as a CMP found in semiconductor clean rooms, is supported by leveler legs  12  each having foot  14 . An adjustable nut  16  turns to lengthen and shorten leg  12  to balance and provide support for manufacturing tool  10 .  
       [0007] Another known tool support uses a rigid welded frame assembly to support heavy equipment, e.g. in the range of hundreds to thousands of lbs. The tool support uses a framework of interconnected steels channels which are welded or bolted to the foundation. Each frame assembly is usually custom built to fit in and around existing structures on the foundation, e.g. pipes, conduits, and drains. The frame assembly is heavy, time consuming and expensive to set-up and maintain, and tends to add contaminants to the clean room environment. The rigid construction of the frame assembly makes it difficult and inflexible to move or re-configure with changes in equipment and clean room layout. If it becomes necessary to move the equipment, substantial planning and re-work to the frame assembly is often needed to meet the foundation slope and drainage requirements and to avoid existing structures and obstacles in the new area. Many times the frame assembly must be completely re-built. Even with careful measurements and planning, unforeseen complications can arise with the many tradespersons co-existing and interfacing in clean room floor access space.  
       SUMMARY OF THE INVENTION  
       [0008] In one embodiment, the present invention is a support member for supporting equipment above a foundation comprising a body having a threaded sleeve, a shaft having a support end for supporting the equipment and a threaded end for screwing into the threaded sleeve of the body to adjust a height of the support member, and first, second, and third legs coupled to the body, wherein each leg includes a vertical channel member in contact with the foundation and a diagonal brace member coupling the vertical channel member to the body.  
       [0009] In another embodiment, the present invention is an adjustable height equipment support stand, comprising a body including an extendable shaft threaded into the body, and first, second, and third legs coupled to the body, wherein each leg includes a vertical channel member and a diagonal brace member coupling the vertical channel member to the body.  
       [0010] In yet another embodiment, the present invention is a method of supporting equipment above a foundation comprising providing a shaft for supporting the equipment, rotating a threaded end of the shaft through a body to raise and lower the equipment, and supporting the body with first, second, and third legs, wherein each leg includes a vertical channel in contact with the foundation and a diagonal brace coupling the vertical channel to the body. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0011]FIG. 1 illustrates a prior art support member for a manufacturing tool;  
     [0012]FIG. 2 illustrates a semiconductor clean room with access floor and tool pedestal assembly;  
     [0013]FIGS. 3 a - 3   c  illustrate quad-pod assemblies supporting a semiconductor manufacturing tool;  
     [0014]FIGS. 4 a  and  4   b  illustrate features of the quad-pod assembly;  
     [0015]FIGS. 5 a  and  5   b  illustrate a quad-pod assembly with shorter legs;  
     [0016]FIGS. 6 a  and  6   b  illustrate a quad-pod assembly with vibration isolation bearing assembly and tie-down rod;  
     [0017]FIGS. 7 a  and  7   b  illustrate a quad-pod assembly with leg extensions;  
     [0018]FIGS. 8 a  and  8   b  illustrate the quad-pod head subassembly;  
     [0019]FIGS. 9 a  and  9   b  illustrate the leg subassembly with vertical pipe member and diagonal brace member;  
     [0020]FIGS. 10 a - 10   c  illustrate the diagonal brace member with various kick angle configurations;  
     [0021]FIGS. 11 a  and  11   b  illustrate a locking net for locking pipe-screw in place;  
     [0022]FIG. 12 illustrates an adaptor puck for reducing rim diameter of the quad-pod head subassembly;  
     [0023]FIG. 13 illustrates a swivel head assembly for the quad-pod head subassembly;  
     [0024]FIG. 14 illustrates a cable tie-down assembly;  
     [0025]FIG. 15 illustrates a shackle and chain tie-down assembly; and  
     [0026]FIGS. 16 a  and  16   b  illustrate a spanner wrench for hand turning the pipe-screw. 
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS  
     [0027] A semiconductor manufacturing clean room area is shown in FIG. 2. An access floor  20  comprises a plurality of rectangular panels or plates  22  supported by stands  24  resting on concrete base, slab on grade, or other solid foundation  25 . The plates  22  may be 24-inches square and manufactured from aluminum. Access floor  20  surrounds tool pedestal assembly  26 . Tool pedestal assembly  26  includes a base plate or table  28  upon which a semiconductor manufacturing tool or equipment is mounted. Base plate  28  is supported by four support assemblies  30 , hereinafter referred to as quad-pods, in contact with foundation  25 . Base plate  28  is raised over or flush with adjacent access floor plates  22 . Diagonal strut  32 , straight ties  34 , and diagonal floor braces  36  provide stiffness for tool pedestal assembly  26  by holding quad-pods  30  together as a rigid braced structural support frame system.  
     [0028] Quad-pod  30  is a load-bearing tool stand or support member suitable for clean room installation in semiconductor facilities for mounting manufacturing tools and other equipment. Quad-pod  30  is constructed with clean room compatible materials and protective coatings. Semiconductor manufacturing tools include equipment which are known to generate vibrations such chemical mechanical polishers (CMP) and other rotating and oscillating machinery, and equipment which are susceptible to vibration such as optical burning tools and etchers, scanning electronic microscopes, and inspection tools.  
     [0029] The manufacturing tool can be mounted onto rigid base plate  28  which is supported by one or more quad-pods  30 . Alternatively, manufacturing tool  40  can be directly mounted to one or more quad-pods  30  such as shown in FIG. 3 a . Quad-pods  30  are positioned under each corner or other loading surface of manufacturing tool  40  to maintain the tool at the desired height above foundation  25 . FIG. 3 b  shows further detail of quad-pod  30  supporting one corner of manufacturing tool  40 . The height of quad-pod  30  can be adjusted to that the bottom surface of manufacturing tool  40  is positioned below, level with, or above access floor  20 . Access floor  20  can easily be placed on all sides of manufacturing tool  40  to provide convenient access to the equipment. FIG. 3 c  illustrates manufacturing tool  40  positioned above access floor  20  with quad-pod  30  extending through a cut-out in one of the access floor plates  22  to support one corner of the manufacturing tool.  
     [0030] Further detail of quad-pod  30  is shown in FIG. 4 a . Quad-pod  30  includes four legs  46 , each having leveler screw and swivel foot assembly  48 . In other embodiments, quad-pod  30  may have three legs  46  or five or more legs  46 . The treaded stem of the leveler screw is screwed into nut  50  which is welded onto the bottom of each leg  46 . Seismic clips or straps  52  are locked by nut  50  to anchor quad-pod  30  securely to foundation  25  in the event of an earthquake or should tool pedestal assembly  26  be jarred or bumped. The swivel foot accommodates for slope in the foundation for drainage. Leg  46  is a welded steel tube and pipe subassembly having a vertical pipe or channel member  80  and a diagonal brace member  90 . The diagonal brace member of legs  46  is pin or socket-mounted to head or body  56 . Head  56  has a threaded sleeve  58 . Pipe-screw  60  is a male-threaded jack screw shaft for supporting, lifting, and leveling manufacturing tool  40  and/or base plate  28 . Pipe-screw  60  threads into sleeve  58  which is a female receptacle. The threading is a square profile, low pitch, and Teflon-coated for ease of lifting under high load. Pipe-screw  60  makes quad-pod  30  adjustable in height to accommodate any distance or clearance between foundation  25  and manufacturing tool  40 . Legs  46  are also individually adjustable with leveler screw and swivel foot assembly  48  to account for unevenness, variation in level, trenches, structures, and obstacles in and around foundation  25 .  
     [0031] To reduce bending moment on the root of legs  46 , a ring  62  is used to hold legs  46  together. Legs  46  are bolted, welded, or pinned to ring  62 . Ring  62  includes additional holes  64  to receive braces, ties, and struts. The top of the vertical pipe member of leg  46  also has a welded nut  66  to receive braces, ties, and struts. Pipe-screw  60  is topped by a welded circular head  68 , which supports a vibration isolation bearing assembly  70 . Isolation bearing assembly  70  provides isolation for vibrations being received from foundation  25  for vibration-sensitive manufacturing tools and other equipment. Isolation bearing assembly  70  also has a swivel head  72  to accommodate pedestal or tool leveling on the fly, i.e. while performing a lifting operation. The lifting is facilitated by lever arms  74  which provide for screwing pipe-screw  60  by hand. Lever arms  74  can unscrew from head  68  when not in use or when horizontal space is limited. Head  68  also has tool socket holes to receive spanner wrench or other special tools for turning pipe-screw  60  by hand. Seismic clips  76 , which are similar to clip  52 , are attached head  72  for anchoring base plate  28  or manufacturing tool  40 . A side view of quad-pod  30  is shown in FIG. 4 b.    
     [0032] A quad-pod  30  is placed under each corner, or other location requiring load support, of base plate  28  and/or manufacturing tool  40 . Legs  46  are in contact with foundation  25  for a solid base. The portion of legs  46  in proximity to foundation  25 , i.e. vertical pipe member  80  and leveler screw and swivel foot assembly  48 , are mechanically isolated from one another. There is no separate bracing between legs  46  on or around vertical pipe member  80  or assembly  48  in the vicinity of foundation  25 . Therefore, with separate and individual vertical channel members  80 , quad-pod  30  can be rotated and oriented so that legs  46  straddle or otherwise avoid any structures and obstacles on and around the foundation. In other words, legs  46  can be positioned over, under, around, or along side existing structures and obstacles such as piping, conduits, ductwork, and drainage. Leveler screw and swivel foot assembly  48  can be adjusted to account for any deformation or slope in the foundation while maintaining the centerline of quad-pod  30  within vertical tolerance. Lever arms  74  turn pipe-screw  60  to raise or lower the overall height of quad-pod  30  and bring isolation bearing assembly  70  and swivel head  72  in contact with and to support base plate  28  and/or manufacturing tool  40 . Quad-pod  30  can adjusted in height by turning pipe-screw  60  to support manufacturing tool  40  at any desired height above foundation  25 . The threaded features of assembly  48  and pipe-screw  60  allow quad-pod  30  to lift, lower, level, and align practically any manufacturing tool. In one embodiment, a quad-pod  30  weighting about 120 lbs can support a load up to 8000 lbs. Quad-pod  30  provides six degrees of freedom: displacements in x-direction, y-direction, and z-direction, and corresponding rotations for each displacement.  
     [0033] Quad-pod  30  is designed and built to accommodate variations in access floor height and slope, leg locations, slant in concrete floor for drainage, trench lines, and to straddle and avoid utility pipes, boxes, conduits, and other fixed structures. Quad-pod  30  can be factory or field assembled and includes telescoping ties, braces, struts, cables, and anchorages. Quad-pod  30  is rigid, strong, light weight, and can be quickly assembled in the field from easily transportable components. The attachment, fixture, and anchor bolts and other hardware are one size fits all and interchangeable.  
     [0034]FIG. 5 a  illustrates another version of quad-pod  30  with shorter vertical pipe members for legs  46  to accommodate shallow access floors  20 . Figure elements having the same or similar function are given the same reference numbers. In this embodiment, the top of the vertical pipe member  80  of leg  46  is capped with plastic plug  82  when not receiving any structural attachments due to the shortness of legs  46 . Diagonal brace members  90  are pinned through slots  86  between head  56  and ring  62  for free rotation of legs  46  to avoid obstacles such as conduits, boxes, tubing, plumbing, and other mechanical structures on or around foundation  25 . Head  56  uses setscrews  84  to lock sleeve  58  in place and setscrews  88  to lock diagonal brace members  90  in place. Setscrew  94  locks head  68  in place. Head  68  receives a shallow, high-load, short-stroke vibration isolation bearing assembly  96 , having a spherical top (button head) part, which receives the pedestal plate. Isolation bearing assembly  96  is designed to reduce vibrations transferred to foundation  25  from vibration-generating tools and equipment being supported by quad-pod  30 . A side view of the shorter version of quad-pod  30  is shown in FIG. 5 b.    
     [0035]FIG. 6 a  illustrates a short quad-pod  30  assembly with isolation bearing assembly  98  having a swivel head  100  to support base plate  28  and/or manufacturing tool  40 . Isolation bearing assembly  98  provides a strong, long stroke vibration isolation feature for quad-pod  30 . The top portion of head  100  swivels independent of isolation bearing assembly  98  to provide rotational freedom and easy of installation and operation in lifting and leveling manufacturing tool  40 . FIG. 6 a  also illustrates tie assembly  106  including threaded rod  108 . Rod  108  screws into vertical pipe member  80 . Nut  110  secures tie assembly  106  to base plate  28  to provide a seismic continuity feature to hold base plate  28  down to quad-pod  30 , which in turn is anchored to foundation  25  by clips  52  as shown in FIG. 4 a . FIG. 6 b  shows a side view of the short quad-pod  30  assembly with isolation bearing assembly  98  and swivel head  100 .  
     [0036]FIG. 7 a  illustrates a quad-pod  30  assembly with vibration isolation bearing assembly  98  and swivel head  100 . A leg extension assembly  116  provides a mechanism to extend the vertical length and increase load bearing capacity of quad-pod  30  while reducing stress on legs  46 . Quad-pod  30  assembly with leg extension assembly  116  can support a heavy load at greater height above foundation  25  without buckling. Leg extension assembly  116  includes vertical pipes or channel members  118  inserted into sleeve  120  of brace or strut-tie assemblies  122 . Vertical pipes  80  also slide into sleeves  120  and both are secured by setscrews  124 . Leg extension assembly  116  is a modulator design which allows multiple leg extension assemblies to be added to further increase the height of quad-pod  30 . With one or more leg extension assemblies  116 , quad-pod  30  can range in height from 0.5 to 7.5 feet or more. FIG. 7 b  shows a side view of the quad-pod  30  assembly with leg extension assembly  116 .  
     [0037]FIG. 8 illustrates the quad-pod head subassembly with pipe-screw  60  and head  68 . Lever arms  74  are bolted or screwed into head  68  to turn pipe-screw  60 . Head  68  has holes  130  for receiving a spanner wrench to hand turn pipe-screw  60 . Head  68  also has setscrew holes  132  to lock mating isolation bearing assembly  70  or  98 , swivel head  72 , base plate  28 , or manufacturing tool  40 . Tapped holes  134  are provide for anchoring seismic clips or tool leg hold-downs. FIG. 8 b  shows a side view of the quad-pod head subassembly.  
     [0038]FIG. 9 a  illustrates leg  46  with telescoping vertical pipe extension  140 . Diagonal brace member  90  is welded to pipe extension  140 . Extension  140  has a length which is inserted into vertical pipe member  80 . Extension  140  can then be adjusted to increase the overall length of leg  46 . Locking nut  144  holds the desired length of extension  140  in place. Leg extensions  140  provide for individual adjustment to the length of legs  46  to account for unevenness and structures in and around foundation  25 . FIG. 9 b  shows a side view of leg  46  with telescoping vertical pipe extension  140 . FIGS. 10 a - 10   c  illustrate diagonal brace members  90  with various kick angle configurations.  
     [0039]FIG. 11 a  illustrates a lock nut  150  for locking pipe-screw  60  in place. Lock nut  150  includes spanner holes  152  for locking tool access and finger rim  154  for easy operation by hand. Lock nut  150  holds pipe-screw  60  securely in place and prevents any loosening, movement, or rattling. FIG. 11 b  shows a top view of lock nut  150 .  
     [0040]FIG. 12 shows an adapter puck  158  for reducing the rim diameter of head  68 . In some lower load bearing applications of quad-pod  30 , it is desirable to use smaller diameter isolation bearing assemblies and swivel bearings. Adaptor puck  158  is mounted to the standard size head  68  such as shown in FIG. 8 a . Each adaptor puck  158  can be sized to receive a different isolation bearing assembly and swivel bearing.  
     [0041]FIG. 13 illustrates a swivel head assembly  160 , which is mounted between head  68  and base plate  28  and/or manufacturing tool  40  to accommodate for any uneven placement or leveling of the load surface. Swivel head assembly  160  has a spherical plug  162  sitting in a matching socket  164  with a Teflon coating for smooth swiveling. Plug  162  rotates freely in angle and orientation with respect to socket  164  to allow quad-pod  30  remain vertical while providing solid and uniform support of the load surface. Swivel head assembly  160  is also useful when foundation  25  is unlevel or uneven. The centerline of quad-pod  30  may be off-vertical while base plate  28  remains horizontal.  
     [0042]FIG. 14 shows a cable tie-down assembly  170  between leg  46  and manufacturing tool  40 . Cable tie-down assembly  170  has an eye ring  172  at one end and loop  174  at the other end with interconnecting cable  176  and cable clip  178 . Eye ring  172  holds manufacturing tool  40  while loop  174  warps around leg  46  to anchor the manufacturing tool or supported equipment in the event of an earthquake or should tool pedestal assembly  26  be jarred or bumped. Base plate  28  has pass-through hole for cable  176 .  
     [0043]FIG. 15 shows an alternate embodiment of the manufacturing tool tie-down assembly with interlocking shackle and chain assembly  180  connecting between leg  46  and manufacturing tool  40 . Shackle and chain assembly  180  provides an anchor for seismic continuity from manufacturing tool  40  passing through base plate  28  to quad-pod  30  and finally to foundation  25  by way of clips  52 .  
     [0044]FIG. 16 illustrates a spanner wrench  190  with handle  192  and welded jigs  194 . Spanner wrench mates in holes  130  to hand rotate pipe-screw  60  and adjust the height of the quad-pod head subassembly. In an alternate embodiment, an electric motor can be used to turn pipe-screw  60  and adjust the height of the quad-pod head subassembly.  
     [0045] As illustrated in the preceding figures, quad-pod  30  is modularly constructed with interchangeable components. This feature allow quad-pod  30  to be easily adapted to the loading requirements, spacing, structures, obstacles, and surface orientation of foundation  25 . Quad-pod  30  can be placed in and around many existing structures and obstacles while accounting for variation in evenness and level of the foundation surface. Quad-pod  30  can then be adjusted to a wide range of heights to match the clearance requirement for manufacturing tool  40  above foundation  25 . Quad-pod  30  supports manufacturing tool- 40  is a variety of environments and conditions. Quad-pod  30  is easily taken down and moveable to setup and support other equipment.  
     [0046] Quad-pod  30  has many other applications. Quad-pod  30  could be used in construction, remodeling, and any other area where there is a need to support an object. Quad-pod  30  provides a convenient and cost effective alternative to fixed frame assemblies and can be adapted to fit in and around the existing environment.  
     [0047] The present invention has been described with respect to preferred embodiment(s). Any person skilled in the art will recognize that changes can be made in form and detail, and equivalents may be substituted for elements of the invention without departing from the spirit and scope of the invention. Many modifications may be made to adapt to a particular situation or material to the teaching of the invention without departing from the essential scope of the invention. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed for carrying out this invention, but that the invention will include all embodiments falling within the scope of the following claims.