Patent Publication Number: US-2022230902-A1

Title: Fall prevention devices and methods

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 63/139,675 filed Jan. 20, 2021, the disclosure of which is hereby incorporated by reference in its entirety. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure generally relates to fall prevention. More particularly, the present disclosure relates to preventing falls from semiconductor processing systems, such as during the installation and/or removal of modules from semiconductor processing systems. 
     BACKGROUND OF THE DISCLOSURE 
     Semiconductor process tools, such as semiconductor process tools used to fabricate semiconductor devices on silicon wafers, commonly employ substrate handling modules and processing modules to manipulate and process silicon substrates. The substrate handling modules generally transfer wafers into the out of the process tool and/or among processing modules of the semiconductor process tool. The processing modules typically form features on the substrates to fabricate the semiconductor device, such as by depositing films onto substrates and/or by etching substrates. 
     Sometimes, it may be necessary to remove and replace a module in a semiconductor process tool. For example, in some semiconductor processing systems, it may be necessary to remove and replace a module to add new capability to the semiconductor process tool. Alternatively (or additionally), it may be necessary to remove and replace a module for reliability or availability reasons, such as in the unlikely event of a failure. Removal and replacement events may, in some semiconductor process tools, require that technician(s) work from elevated workspaces during the removal and replacement event. Such work may expose the technician(s) to risk of injury in the event of fall from the elevated workspace. 
     Various devices exist to limit the risk of injury from falls from elevated workspaces. For example, safety railings may be positioned in and around elevated workspace. Safety netting may be positioned around elevated workspaces. And safety tie-offs distributed within the elevated workspace may cooperate with safety harnesses worn by technicians doing work from elevated workspaces to limit risk of injury in the event of fall from the elevated workspace. 
     Such fall prevention devices and fall prevention methods have generally be acceptable for their intended purpose. However, there remains a need in the art for improved fall prevention devices and methods of preventing falls from elevated workspaces. The present disclosure provides a solution to this need. 
     SUMMARY OF THE DISCLOSURE 
     A gate/barrier assembly for a semiconductor processing system is provided. The gate/barrier assembly includes a first post configured to be fixedly supported by a semiconductor processing system; a second post extending in parallel with the first post and configured to be pivotably supported by the semiconductor processing system; a gate pivotably supported by the first post and having a closed position and an open position, the gate overlapping the second post in the closed position, the gate spaced apart from the second post in the open position; and a barrier fixedly supported by the second post and having a guard position and a guide position, the barrier abutting the first post in the guard position, the barrier spaced apart from first post in the guide position. The gate overlaps the barrier when the gate is in the closed position and the barrier is in the guard position. 
     In certain examples, the gate/barrier assembly may include a biasing member arranged between the gate and the first post. The biasing member may urge the gate toward the closed position to automatically move the gate between the closed position and the open position. 
     In certain examples, the gate/barrier assembly may have a first post flange. The first post flange may extend about the first post to fixedly support the first post adjacent to a passthrough of the semiconductor processing system. 
     In certain examples, the gate/barrier assembly may have a second post flange. The second post flange may extend about the second post to pivotably support the second post opposite the first post. The second post may be spaced from the first post by a passthrough of the semiconductor processing system. 
     In certain examples, the gate/barrier assembly may include a gate midrail. The gate midrail may extend horizontally relative to the first post. The gate midrail may be spaced from the semiconductor processing system by less than 500 millimeters (about 19.7 inches). A gate toprail may extend in parallel with the gate midrail. The gate toprail may be spaced from the gate midrail by less than 500 millimeters (about 19.7 inches). 
     In certain examples, the gate may include an inboard portion and an outboard portion. The inboard portion may be pivotably supported by the first post. The outboard portion may be pivotably supported by the inboard portion of the gate and therethrough by the first post. The outboard portion of the gate may have an extended position and a folded position, the outboard portion of the gate abutting the inboard portion of the gate in extended position, the outboard portion of the gate overlaying the inboard portion of the gate in the folded position. 
     In certain examples, the gate/barrier assembly may include a barrier midrail. The barrier midrail may be fixed to the second post. The barrier midrail may extend horizontally from the second post. The barrier midrail may be spaced from the semiconductor processing system by less than 500 millimeters (about 19.7 inches). A barrier toprail may be fixed to the second post. The barrier toprail may extend in parallel with the barrier midrail. The barrier toprail may be spaced from the barrier midrail by less than 500 millimeters (about 19.7 inches). 
     In certain examples, the gate/barrier assembly may include a first bracket. The first bracket may be fixed to the semiconductor processing system. The bracket may define therein two or more first bracket fastener apertures. The two or more first post fasteners may extend through the two or more first bracket fastener apertures. The two or more first post fasteners may fix the first post to the first bracket. 
     In certain examples, the gate/barrier assembly may include a second bracket. The second bracket may be fixed to the semiconductor processing system. The second bracket may define therein two or more second bracket fastener apertures. Two or more second post fasteners may extend through the two or more second bracket fastener apertures. The two or more second post fasteners may fix the second post to the second bracket. 
     In certain examples, the number of second bracket fastener apertures may be greater than the number of second post fasteners to pivotably fix the barrier to the semiconductor processing system for moving the barrier between the guard position and the guide position. 
     In certain examples, the number of second post threaded apertures may be greater than the number of second post fasteners to pivotably fix the barrier to the semiconductor processing system for moving the barrier between the guard position and the guide position. 
     In certain examples, the gate/barrier assembly may include a latch member. The latch member may be fixed to one of the barrier and the gate to fix the gate to the barrier when the gate is in the closed position. 
     In certain examples, the gate may overlap an inboard facing surface of the second post when in the closed position. The barrier may abut a surface of the first post facing the second post when in the closed position. 
     In certain examples, the gate may be fixed to the barrier when the barrier is in the guard position. The gate may be fixed to the barrier when the barrier is in the guide position. 
     In certain examples, the gate/barrier assembly may include a hinge. The hinge may connect the gate to the first post. A biasing member may be arranged between the gate and the first post. The biasing member may be configured to urge the gate toward the closed position. A catch mechanism may be operably associated with the hinge and configured to retain the gate in the open position. 
     A semiconductor system is provided. The semiconductor processing system includes a wafer handling chamber, a wafer handler, and a gate/barrier assembly as described above. The wafer handling chamber is positioned above a floor and has a workspace and a passthrough that are elevated relative to the floor. The wafer handler is be housed within the wafer handling chamber. The first post of the gate/barrier assembly is fixed to the wafer handling chamber, the second post of gate/barrier assembly is pivotably fixed to the wafer handling chamber, and the second post is spaced from the first post by the passthrough. The gate of the gate/barrier assembly spans the passthrough in the closed position and the barrier of the gate/barrier assembly spans the passthrough in the guard position. 
     In certain examples, the gate of the gate/barrier assembly may extend inboard from the passthrough in the open position. The barrier of the gate/barrier assembly may extend outboard from the passthrough in the guide position. 
     In certain examples, the semiconductor processing system may include a staircase. The staircase may be connected to the wafer handling chamber to provide access to the workspace from the floor. A rail may extend above the wafer handling chamber. The rail may be supported by the wafer handling chamber. The rail may extend above the passthrough between an inboard hoisting location and an outboard hoisting location. A trolley-mounted hoist may be slidably disposed along the rail for transfer of the wafer handler module into and from the workspace. 
     A method of removing and replacing a module in a semiconductor processing system is provided. The method includes, at a semiconductor processing system including a gate/barrier assembly as described above, hoisting a wafer handler module from the semiconductor processing system. The gate of the gate/barrier assembly is moved to the open position, the barrier of the gate/barrier assembly is moved to the guide position; and the wafer handler module is transferred through the passthrough of the semiconductor processing system. The gate of the gate/barrier assembly automatically moves to the closed position as the wafer handler module traverses the passthrough. 
     In certain examples, the method may include removably fixing the gate to the barrier while the gate is in the closed position and the barrier is in the guide position. 
     In certain examples, the method may include moving the gate from the open position by releasing a catch mechanism operably associated with the gate. 
     In certain examples, the method may include moving an outboard portion of the gate from an extended position to a folded position. Once in the folded position, a chamber lid may be transferred through space previously occupied by the outboard portion in the extended position. 
     This summary is provided to introduce a selection of concepts in a simplified form. These concepts are described in further detail in the detailed description of examples of the disclosure below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
       These and other features, aspects, and advantages of the present disclosure herein are described below with reference to the drawings of certain embodiments, which are intended to illustrate and not to limit the present disclosure. 
         FIG. 1  is a perspective view of a semiconductor processing system having an elevated workspace and a module passthrough, showing a gate/barrier assembly connected to the semiconductor processing system at the passthrough to prevent falls from the elevated workspace; 
         FIG. 2  is a perspective view of a portion of the semiconductor processing system of  FIG. 1  including the gate/barrier assembly, showing a gate and a barrier of the gate/barrier assembly spanning the passthrough in a closed position and a guard position, respectively; 
         FIG. 3  is a perspective view of the gate/barrier assembly of  FIG. 1  looking toward the gate/barrier assembly from outboard of the semiconductor processing system, showing the gate pivotably supported by a first post and the barrier fixedly supported by a second post; 
         FIG. 4  is a perspective view of the gate/barrier assembly of  FIG. 1  looking toward the gate/barrier assembly from inboard of the semiconductor processing system, showing a hinge connecting the gate to the first post and a spring operatively connected to the gate; 
         FIG. 5  is a perspective view of a portion of the semiconductor processing system of  FIG. 1  including the gate/barrier assembly, showing a wafer handler module being hoisted from the semiconductor processing system while the gate and the barrier span the passthrough in the closed position and the guard position, respectively; 
         FIG. 6  is a perspective view of a portion of the semiconductor processing system of  FIG. 1  including the gate/barrier assembly, showing the gate in an open position and the barrier in the guard position for movement of the wafer handler module to the passthrough; 
         FIG. 7  is a perspective view of a portion of the semiconductor processing system of  FIG. 1  including the gate/barrier assembly, showing the barrier in a guide position while the gate remains in the open position in preparation for transfer of the wafer handler module through the passthrough to an outboard hoisting location; 
         FIG. 8  is a perspective view of a portion of the semiconductor processing system of  FIG. 1  including the gate/barrier assembly, showing the gate automatically moving to the closed position as a technician on the floor adjacent to the passthrough transfers the wafer handler module to the outboard hoisting location; 
         FIG. 9  is a perspective view of a portion of the semiconductor processing system of  FIG. 1  including the gate/barrier assembly, showing a technician lowering the wafer handler module from the semiconductor processing system from the elevated workspace while the gate remains in the closed position and the barrier remains in the guide position; 
         FIGS. 10 and 11  are perspective and plan views of the gate/barrier assembly according to another example the present disclosure, showing a split gate in an extended position and a folded position during removal of a cover overlaying the wafer handling module, respectively; and 
         FIG. 12  is a block diagram of a method of removing and replacing a module in a semiconductor processing system, showing operations of the method according to an illustrative and non-limiting example of the method. 
     
    
    
     It will be appreciated that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the relative size of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of illustrated embodiments of the present disclosure. 
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an example of a gate/barrier assembly in accordance with the disclosure is shown in  FIG. 1  and is designated generally by reference character  100 . Other embodiments of gate/barrier assemblies, semiconductor processing systems including gate/barrier assemblies, and methods of removing and replacing modules in semiconductor processing systems in accordance with the present disclosure, or aspects thereof, are provided in  FIGS. 2-12 , as will be described. The systems and methods described herein may be used for to prevent falls from elevated workspaces during installation and/or replacement of modules in semiconductor processing systems, such as during installation and/or replacement of wafer handler modules in chemical vapor deposition (CVD) and atomic layer deposition (ALD) semiconductor processing systems, though the present disclosure is not limited to wafer handler modules or to any particular type of semiconductor processing system in general. 
     Referring to  FIG. 1 , a semiconductor processing system  10  is shown. The semiconductor processing system  10  is arranged on a floor  12 , e.g., in a cleanroom, and includes a wafer handling chamber  14 , a wafer handler module  16  (shown in  FIG. 5 ), a first processing module  18 , and one or more second processing module  20 . The wafer handling chamber  14  is supported above the floor  12 , houses the wafer handler module  16  and includes a gate valve  22 . The gate valve  22  is configured to transfer substrates, e.g., silicon wafers, into and out of the semiconductor processing system  10  via the wafer handling chamber  14 . 
     The wafer handler module  16  (shown in  FIG. 5 ) is configured to transfer wafers between the gate valve  22 , the first processing module  18 , and/or the one or more second processing module  20 . In certain examples, the wafer handler module  16  may be a first wafer handler module  16  and the semiconductor processing system  10  may include a second wafer handler module  40  housed within the wafer handling chamber  14 . For example, the first wafer handler module  16  may be a front-end wafer handler module and the second wafer handler module  40  may be a back-end wafer handler module. A loadlock module may be arranged between the first wafer handler module  16  and the second wafer handler module  40 . 
     The first processing module  18  and the one or more second processing module  20  are configured for depositing films and/or etching substrates received from the wafer handler module  16  (shown in  FIG. 5 ). In this respect the first processing module  18  and the one or more second processing module  20  are arranged on the floor  12 , abut the wafer handling chamber  14 , and are laterally adjacent to one another. In certain examples, at least one of the first processing module  18  and second processing module  20  may be a CVD processing module. In accordance with certain examples, at least one of the first processing module  18  and the second processing module  20  may be an ALD processing module. In the illustrated example the semiconductor processing system has eight (8) processing modules. This is for illustration purposes and is non-limiting. As will be appreciated by those of skill in the art in view of the present disclosure, semiconductor processing systems having fewer than eight (8) processing modules or more than eight (8) processing modules may also benefit from the present disclosure. 
     With reference to  FIG. 2 , as has been explained above, it may sometimes be necessary to install/replace modules from a semiconductor processing system, e.g., the wafer handler module  16  (shown in  FIG. 5 ), such as to upgrade or repair a module of the semiconductor processing system. To facilitate installation/removal of the wafer handler module  16  the semiconductor processing system  10  has a workspace  24  and a passthrough  26 , and includes a staircase  28 , a rail  30 , and a trolley-mounted hoist  32 . The workspace  24  is defined along the top of the wafer handling chamber  14  and is located above the wafer handler module  16 . The workspace  24  extends between an inboard hoisting location  34  and an outboard hoisting location  36 , and traverses the passthrough  26 . It is contemplated that the workspace  24  be further accessible by technicians through the staircase  28 , which is supported by the wafer handling chamber  14  to provide access to the workspace  24  for technicians from the floor  12 . 
     The passthrough  26  is located within a gap defined between the first processing module  18  (shown in  FIG. 1 ) and the second processing module  20  (shown in  FIG. 1 ), is elevated with respect to the floor  12 , and separates the inboard hoisting location  34  from an outboard hoisting location  36  located above the floor  12 . The elevated workspace  24  extends along an upper surface of the wafer handling chamber  14  to the passthrough  26 , both the elevated workspace  24  and the passthrough  26  being elevated relative to the floor  12 . The rail  30  is supported above the semiconductor processing system  10 , e.g., by frames extending upwards from and supported by the wafer handling chamber  14  and spans an upper surface of the wafer handling chamber  14  between the inboard hoisting location  34  and the outboard hoisting location  36 . The trolley-mounted hoist  32  is slidably disposed along the rail  30 , carries a hoisting mechanism thereon for hoisting and lowering the wafer handler module  16 , and is movable along the rail  30  between the inboard hoisting location  34  and the outboard hoisting location  36 . In certain example, the workspace  24  may be elevated above the floor  12  by a height sufficient to invoke the safeguard prescribed in SEMI S2-0818, ENVIRONMENTAL, HEALTH, AND SAFETY GUIDELINE FOR SEMICONDUCTOR MANUFACTURING EQUIPMENT, approved for publication on Aug. 17, 2018 (hereafter “SEMI S2-0818”). In accordance with certain examples, the passthrough  26  may be elevated above the floor  12  by about 1.2 meters (about 4 feet). It is contemplated that the trolley-mounted hoist  32  may include a manual hoisting mechanism, e.g., a crank-operated hoisting mechanism. 
     As has been explained above, work in elevated workspaces may be accompanied by the risk of injury due to falls. For example, technicians working in the elevated workspace  24  may risk injury in the event of fall from the top of the wafer handling chamber  14 . Technicians working on the elevated workspace  24  may also risk injury when installing and/or removing the wafer handler module  16  from the wafer handling chamber  14 . And technicians working on the elevated workspace  24  may further risk injury when transferring the wafer handling module to and from and the semiconductor processing system  10  through the passthrough  26 . To limit (or eliminate) risk of injury due to fall during one or more of these tasks, the semiconductor processing system  10  includes the gate/barrier assembly  100 . 
     With reference to  FIG. 3 , the gate/barrier assembly  100  is configured for placement of at least one (or both) of a barrier  110  (shown in  FIG. 3 ) and a gate  102  (shown in  FIG. 4 ) in the passthrough  26  to prevent (or eliminate entirely) risk of fall from the elevated workspace  24  through the passthrough  26 . In this respect the gate/barrier assembly  100  includes the gate  102 , a first post  104 , a hinge  106  (shown in  FIG. 4 ) and a biasing member  108  (shown in  FIG. 4 ). As also shown in  FIG. 3 , the gate/barrier assembly  100  also includes the barrier  110 , a second post  112  and a latch member  114 . As further shown in  FIG. 3 , the gate/barrier assembly  100  further includes a first bracket  116 , a second bracket  118 , a plurality of first post fasteners  120  and a plurality of second post fasteners  122 . 
     The first post  104  has a first post lower portion  124 , a first post upper portion  126  and a first post flange  128 . The first post lower portion  124 , the first post upper portion  126 , and the first post flange  128  are each arranged along a first post axis  130 . The first post flange  128  extends about the first post  104  and the first post axis  130 , separates the first post lower portion  124  from the first post upper portion  126 , and is configured for seating against the first bracket  116 . The first post lower portion  124  extends upwards from the first post flange  128 , i.e., in a direction axially opposite the first post upper portion  126 , defines therein a plurality of first post threaded apertures  132 , and is configured to seat in the first bracket  116 . The plurality of first post threaded apertures  132  are axially spaced from one another along the first post axis  130  at a common circumferential position about the first post axis  130  for fixing the first post  104  to the first bracket  116 . 
     The first bracket  116  is configured for fixation to the semiconductor processing system  10  (shown in  FIG. 1 ). More specifically, the first bracket  116  is configured to fix the first post  104  to the semiconductor processing system  10  at a location below the passthrough  26  (shown in  FIG. 2 ) such that the first post  104  laterally bounds the passthrough  26 . In this respect the first bracket  116  is connected to the wafer handling chamber  14  below the passthrough  26 , defines therein a first bracket socket  134 , and has a plurality of first bracket fastener apertures  136 . The plurality of first bracket fastener apertures  136  extend through the first bracket  116  to the first bracket socket  134  and are configured to receive therethrough the plurality of first post fasteners  120  for fixation of the first post  104  to the first bracket  116 . 
     The first post lower portion  124  is slidably received in the first bracket socket  134  such that the first post flange  128  seats against an upper surface of the first bracket  116 . Seating the first post flange  128  against the upper surface of the first bracket  116  positions the first post threaded apertures  132  and the first bracket fastener apertures  136  at a common axial location about the first post axis  130 . The common axial location facilitates assembly of the first post  104  in the first bracket  116  by registering the first bracket fastener apertures  136  with the first post threaded apertures  132 , simplifying the insertion of the plurality of first post fasteners  120  through the plurality of first bracket fastener apertures  136  and seating within the plurality of first post threaded apertures  132 . Threaded engagement of the plurality of first bracket fasteners  120  fixedly supports the first post  104  at the passthrough  26  (shown in  FIG. 1 ) via the first bracket  116 . 
     In certain examples, the number of first post fasteners  120  may be equivalent to the number first bracket fastener apertures  136 . In accordance with certain examples, the number of first post fasteners  120  may be equivalent to the number of first post threaded apertures  132 . It is also contemplated that, in certain examples, the number of first post fasteners  120  may be equivalent to both the number of first bracket fastener apertures  136  and the number of first post threaded apertures  132 . As will be appreciated by those of skill in the art in view of the present disclosure, matching the number of fasteners with fastener apertures may error-proof assembly of the first post  104  in the first bracket  116  by limiting the installation to a single orientation about the first post axis  130 . It is contemplated that, in certain examples, the first post lower portion  124  and first bracket socket may have a key portion and corresponding keyway portion to further simplify assembly of the gate/barrier assembly  100  on the semiconductor processing system  10 . 
     With reference to  FIG. 4 , the first post upper portion  126  extends axially upwards from the flange  128  along the first post axis  130 . The hinge  106  is connected to the first post upper portion  126  and couples the gate  102  to the first post  104 . In this respect the hinge  106  pivotably fixes the gate  102  to the first post  104  along the first post upper portion  126  such that the gate  102  is pivotable relative to the first post  4  between an open position  138  (shown in  FIG. 6 ) and a closed position  140  (shown in  FIG. 2 ). In the open position  138 , the gate  102  extends inboard from the passthrough  26 , is spaced from the second post  112  and provides limited fall prevention protection. In the closed position  140 , the gate  102  spans the passthrough  26 , overlaps an inboard surface of the second post  112 , and limits (or prevents entirely) risk of fall from the workspace  24  and through the passthrough  26 . 
     The biasing member  108  is connected between the first post  104  and the gate  102  and is configured to exert a biasing force on the gate  102  urging the gate  102  toward the closed position  140  (shown in  FIG. 2 ). As will be appreciated by those of skill in the art in view of the present disclosure, urging the gate  102  toward the closed position  140  enables the gate  102  to close automatically, limiting (or eliminating) risk of fall through the passthrough  26  by eliminating the need for a technician to mount the wafer handling chamber  14  and manually move the gate  102  to the closed position  140  while located on the elevated workspace  24 . In certain examples, the biasing member  108  may include a spring, such as a coil spring. In accordance with certain examples, the biasing member  108  and the hinge  106  may be integrated as a single assembly, simplifying assembly and/or removal of the gate/barrier assembly  100  from the semiconductor processing system  10  (shown in  FIG. 1 ). A fixation member, accessible from the floor  12  (shown in  FIG. 1 ), may further be operably associated with the gate  102  to fix the gate  102  in the open position  138  (shown in  FIG. 6 ). 
     The gate  102  may have a gate toprail  142 , gate midrail  144 , a gate first vertical member  146 , and a gate second vertical member  148 . The gate toprail  142  extends horizontally from the first post  104  and has a length substantially equivalent (or equivalent) to a width of the passthrough  26  (shown in  FIG. 2 ). The gate midrail  144  similarly extends horizontally from the first post  104 , also has a length substantially equivalent (or equivalent) to a width of the passthrough  26  and is further arranged in parallel with the gate toprail  142 . The gate first vertical member  146  connects the gate toprail  142  to the gate midrail  144 , is substantially orthogonal (or orthogonal) to both the gate toprail  142  and the gate midrail  144  and extends in parallel with the first post upper portion  126  of the first post  104 . The gate second vertical member  148  connects the gate toprail  142  to the gate midrail  144 , is substantially orthogonal (or orthogonal) to the gate toprail  142  and the gate midrail  144  and extends in parallel with the gate first vertical member  146 , and is further horizontally spaced from the gate first vertical member  146  by both the gate toprail  142  and the gate midrail  144 . It is contemplated that the hinge  106  may be connected to the gate first vertical member  146  to pivotably support the gate  102  with the first post  103 . It is also contemplated that, in certain examples, the latch member  114  (shown in  FIG. 3 ) may seat on (or be configured to removably engage) the gate second vertical member  148 . 
     In certain examples, the gate midrail  144  may be spaced from the top of the wafer handling chamber  14  (shown in  FIG. 1 ) by less than 500 millimeters (about 19.7 inches). In accordance with certain examples, the gate toprail  142  may be spaced from the gate midrail  144  by less than 500 millimeters (about 19.7 inches). As will be appreciated by those of skill in the art in view of the present disclosure, spacing the gate midrail  144  less than 500 millimeters (about 19.7 inches) from the top of the wafer handling chamber  14  (shown in  FIG. 1 ), and the gate toprail  142  from the gate midrail  144  by less than 500 millimeters (about 19.7 inches), renders the semiconductor processing system  10  compliant with SEMI S2-0818 when the gate  102  is in the closed position  140  (shown in  FIG. 2 ). 
     With continuing reference to  FIG. 3 , the second post  112  is similar to the first post  104  and in this respect has a second post lower portion  150 , a second post upper portion  152  and a second post flange  154 . The second post lower portion  150 , the second post upper portion  152  and the second post flange  154  are each arranged along a second post axis  156 . The second post flange  154  extends about the second post  112  and the second post axis  156  and separates the second post lower portion  150  from the second post upper portion  152 . The second post lower portion  150  extends from the second post flange  154  downward, i.e., in a direction opposite the second post upper portion  152  and defines therein a plurality of second post threaded apertures  158 . The second post upper portion  152  extends axially upwards from the second post flange  154 , along the second post axis  156 , and fixedly supports the barrier  110 . 
     The barrier  110  has a barrier toprail  168 , a barrier midrail  170 , and a barrier vertical member  172 . The barrier toprail  168  extends horizontally from the second post  112  to the barrier vertical member  172  and has a length substantially equivalent (or equivalent) to a width of the passthrough  26  (shown in  FIG. 2 ). The barrier midrail  170  extends horizontally from the second post  112  to the barrier vertical member  172 , has a length substantially equivalent (or equivalent) to the width of the passthrough  26 , and further extends in parallel with the barrier toprail  168 . The barrier vertical member  172  connects the barrier toprail  168  to the barrier midrail  170 , is orthogonal relative to both the barrier toprail  168  and the barrier midrail  170  and extends in parallel with the second post  112 . In certain examples, the latch member  114  may seat on (or be configured to removably engage) the barrier toprail  168 . In accordance with certain examples, the latch member  114  may seats on (or is removably engaged) to the barrier at a location along the second post axis  156 . As will be appreciated by those of skill in the art, this allows the gate  102  to be fixedly latched to the barrier  110  irrespective of the position of the barrier  110 , e.g., when the barrier  110  is in a guard position  164  (shown in  FIG. 2 ) wherein the barrier spans the passthrough  26  and a guide position  166  (shown in  FIG. 7 ) wherein the barrier  110  extends from the passthrough  26 . 
     In certain examples, the barrier midrail  170  may be spaced from the top of the wafer handling chamber  14  (shown in  FIG. 1 ) by less than 500 millimeters (about 19.7 inches). In accordance with certain examples, the barrier toprail  168  may be spaced from the barrier midrail  170  by less than 500 millimeters (about 19.7 inches). As will be appreciated by those of skill in the art in view of the present disclosure, spacing (a) the barrier midrail  170  less than 500 millimeters (about 19.7 inches) from the top of the wafer handling chamber  14  (shown in  FIG. 1 ), and (b) the barrier toprail  168  by less than 500 millimeters (19.7 inches) from the barrier midrail  170 , renders the semiconductor processing system  10  (shown in  FIG. 1 ) compliant with SEMI S2-0818 when the gate  102  is in the closed position  140  (shown in  FIG. 2 ). 
     The second bracket  118  is configured to pivotably fix the second post  112  to the semiconductor processing system  10  (shown in  FIG. 1 ). More specifically, the second bracket  118  is configured to fix the second post  112  to the semiconductor processing system  10  at a location below the passthrough  26  (shown in  FIG. 1 ), laterally bounding the passthrough  26 , and spaced from the first post  104  by the passthrough  26 . In this respect the second bracket  118  is connected to the wafer handling chamber  14  (shown in  FIG. 1 ) below the passthrough  26 , defines therein a second bracket socket  160 , and has a plurality of second bracket fastener apertures  162 . 
     The second post lower portion  150  is slidably received in the second bracket socket  160  such that the second post flange  154  seats on top of the second bracket  118 . Seating the second post flange  154  on the top the second bracket  118  positions the second post threaded apertures  158  and the second bracket fastener apertures  162  on common circumferences about the second post axis  156 . Positioning the second post threaded apertures  158  and the second bracket fastener apertures  162  on common circumference allows the second post  112  (and thereby the barrier  110 ) to be pivoted in the second bracket  118  about the second post axis  156  to register different pairs of the second post threaded apertures  158  and the second bracket fastener apertures  162 . For example, the second post  112  may pivoted to locate the either the guard position  164  (shown in  FIG. 2 ) and the guide position  166  (shown in  FIG. 7 ), and the second post  112  fastened to the second bracket  118  using the plurality of second post fasteners  122  to fix the barrier  110  in either the guard position  164  or the guide position  166 . 
     In certain examples, two of the plurality of second post threaded apertures  158  may be circumferentially offset from one another about the second post axis  156  for fixation of the barrier  110  in to the second bracket  118  in both the guard position  164  and the guide position  166 . In accordance with certain examples, two of the plurality of second bracket fastener apertures  162  may be circumferentially offset from one another about the second post axis  156  for fixation of the barrier  110  in to the second bracket  118  in both the guard position  164  (shown in  FIG. 2 ) and the guide position  166  (shown in  FIG. 7 ). It is contemplated that, in accordance certain examples, the plurality second bracket threaded apertures  162  may be greater than the plurality of second post fasteners  122  for pivotably fixing the barrier to the semiconductor processing system for moving the barrier between the guard position  164  and the guide position  166 . It is further contemplated that the plurality second post threaded apertures  158  may be greater than the plurality of second post fasteners  122  to pivotably fix the barrier  110  to the semiconductor processing system  10  for movement of the barrier  110  between the guard position  164  and the guide position  166 . 
     Referring now to  FIGS. 5-9 , a method  200  of removing and replacing module in a semiconductor processing system, e.g., the wafer handler module  16 , is shown. As shown in  FIG. 5 , the gate  102  and the barrier  110  are first positioned in the passthrough  26  by moving the gate  102  and the barrier  110  to the closed position  140  and the guard position  164 , respectively. Moving the gate  102  to the closed position  140  includes (a) pivoting the gate  102  about the first post  104  from open position  138 , and (b) retaining the gate  102  in the passthrough  26  by overlapping the gate second vertical member  148  against an inboard surface of the second post  112 , Moving the barrier  110  to the guard position  164  includes (c) removing the plurality of second post fasteners  122  from the second post  112 ; (d) pivoting the second post  112  (and thereby the barrier  110 ) about the second post axis  156 , and (e) fixing the second post  112  in the second bracket  118  by threadedly seating the plurality of second post fasteners  122  in the second post  112  through the plurality of second bracket fastener apertures  162  in the second bracket  118 . 
     Once the gate is moved to the closed position  140  and the barrier  110  moved to the guard position  164 , the wafer handler module  16  is removed from the semiconductor processing system  10 . Removal of the wafer handler module  16  may be accomplished by (f) sliding the trolley-mounted hoist  32  along the rail  30  to the inboard hoisting location  34 , (g) removing covers from the wafer handling chamber  14  to access and rig the wafer handler module  16  for lifting, and (g) hoisting the wafer handler module  16  from the wafer handling chamber  14 , e.g., by manipulating a crank operably associated with the trolley-mounted hoist  32 . Optionally, the gate  102  may be fixed to the barrier  110  by (h) latching the gate  102  to the barrier  110  with the latch member  114  to prevent movement of the gate  102  from the closed position  140 , e.g., in the event that the gate  102  is bumped during removal and/or movement of the wafer handler module  16 . As will be appreciated by those of skill in the art in view of the present disclosure, moving the gate  102  to the closed position  140  positions the gate  102  in the passthrough  26 . Positioning the gate  102  in the passthrough allows the gate/barrier assembly  100  to limit (or prevent) risk of fall from the workspace  24  through the passthrough  26 . 
     As shown in  FIG. 6 , next, the wafer handler module  16  is readied for transfer through the passthrough  26 . Readying the wafer handler for transfer through the passthrough  26  includes (a) moving the gate  102  to the open position  138  by pivoting the gate  102  about the first post  104  such that the gate  102  extends inboard from the passthrough  26 , (b) fixing the gate  102  in the open position  138 , and (c) moving the trolley-mounted hoist  32  (and thereby the wafer handler module  16 ) from the inboard hoisting location  34  to an inboard intermediate location  38  (shown in  FIG. 2 ) adjacent the passthrough  26  and spaced from the outboard hoisting location by the passthrough  26 . Fixation of the gate  102  in the open position  138  may be accomplished, for example, by (d) manipulating a catch mechanism  174  (shown in  FIG. 7 ) positioned below the biasing member  108  and operably associated with the gate  102 . Optionally, movement of the gate  102  to the open position  138  may be preceded by (e) disengaging the latch member  114  from one of the gate  102  and the barrier  110  to unfix the gate  102  from the barrier  110 . Notably, as the barrier  110  remains the guard position  164  during these operations, the gate/barrier assembly  100  also limits (or eliminates) risk of fall from the workspace  24  through the passthrough  26  during these operations. 
     As shown in  FIG. 7 , the barrier  110  is thereafter moved to the guide position  166 . Moving the barrier  110  to the guide position  166  includes (a) unfixing the second post  112  from the semiconductor processing system  10  by removing the plurality of second post fasteners  122  (shown in  FIG. 3 ) from the second post  112  and the second post bracket  118 , (b) pivoting the second post  112  (and thereby the barrier  110 ) the second post axis  156  (shown in  FIG. 3 ) such that the barrier  110  extends outboard from the passthrough  26 , and (c) fixing the second post  112  to the semiconductor processing system  10  by seating the plurality of second post fasteners  122  in the second post threaded apertures  158  through the second bracket fastener apertures  162  of the second post bracket  118 . Notably, these operations may be accomplished from the floor  12 . 
     In the guide position  166  the barrier  110  is spaced from the first post  104  such that the barrier  110  extends from the passthrough  26  in an outboard direction. Notably, as plurality of second post fasteners  122  are seated in the second post bracket  118  at a location below the passthrough  26 , are therefore accessible from a technician located on the floor  12 , the gate/barrier assembly  100  further limits (or eliminates entirely) risk of fall from the workspace  24  through the passthrough  26  during movement of the barrier  110  to the guide position  166 . 
     As shown in  FIG. 8 , next, the wafer handler module  16  is transferred through the passthrough  26 . Transfer of the wafer handler module  16  through the passthrough is accomplished by moving the gate  102  from the open position  138  (shown in  FIG. 7 ) to an intermediate position  176  (shown in  FIG. 7 ) located between the open position  138  and the closed position  140  (shown in  FIG. 2 ) by pivoting the gate  102  about the first post  104 . The wafer handler module  16  is then moved the passthrough  26  from the inboard intermediate location  38  adjacent to the passthrough  26  to the outboard hoisting location  36 . Notably, as the wafer handler module  16  moves through the passthrough  26 , the gate  102  moves from the intermediate position  176  to the closed position  140 . It is contemplated that movement of the gate  102  to the closed position  140  occur automatically, i.e., without manipulation by a technician, the gate/barrier assembly  100  thereby limiting (or eliminating) risk without requiring a technician to first position the gate  102  in the closed position  140 . 
     Optionally, moving the gate  102  from the open position  138  to the intermediate position  176  may include (d) releasing the catch mechanism  174  (shown in  FIG. 7 ), the gate  102  thereby being supported in the intermediate position  176  by the wafer handler module  16 . So supported, the biasing force exerted by the biasing member  108  (shown in  FIG. 3 ) drives the wafer handler module  16  through the passthrough  26  by the engagement of the gate  102  against the wafer handler module  16 . Alternatively, moving the gate  102  from the open position  138  to the intermediate position  176  may include (e) manipulating the wafer handler module  16  by a technician on the floor  12  to move between the inboard intermediate location  38  adjacent to the passthrough  26  and the outboard hoisting location  36 . Notably, as transfer of the wafer handler module  16  may be accomplished from the floor  12 , the gate/barrier assembly  100  also limits (or eliminates) risk of fall from the workspace  24  through the passthrough  26  during transfer of the wafer handler module  16  through the passthrough  26 . 
     As shown in  FIG. 9 , the wafer handler module  16  is thereafter lowered from the outboard hoisting location  36 . Lowering the wafer handler module  16  from the outboard hoisting location  36  includes (a) mounting the staircase  28  to access the workspace  24 , (b) fixing the gate  102  to the barrier  110  with the latch member  114 , and (c) lowering the wafer handler module  16  by manipulating the crank operably associated with the trolley-mounted hoist  32 . As will be appreciated by those of skill in the art in view of the present disclosure, replacement of the wafer handler module  16  in the semiconductor processing system  10  may be accomplished by reversing the operations shown in  FIGS. 5-9  while also limiting (or preventing entirely) risk of fall from the workspace  24  through the passthrough  26 . 
     With reference to  FIGS. 10 and 11 , a gate/barrier assembly  300  is shown. The gate/barrier assembly  300  is similar to the gate/barrier assembly  100  (shown in  FIG. 1 ) and additionally includes a gate  302  with an inboard portion  304  and an outboard portion  306 . The outboard portion  304  is movable relative to the inboard portion  304  between an extended position  308  (shown in  FIG. 10 ) and a folded position  310  (shown in  FIG. 11 ), the outboard portion  306  abutting the inboard portion  304  in the in extended position  308 , the outboard portion  306  overlaying the inboard portion  304  in the folded position  310 . As will be appreciated by those of skill in the art in view of the present disclosure, moving the outboard portion  306  of the gate  302  to the folded position  310  limits intrusion of the gate  302  into the workspace  24  when the gate is in the open position  138  while providing the aforementioned advantages with respect to fall protection. Limiting intrusion of the gate  302  into the workspace  24  in turn allows for removal of relatively large structures from the semiconductor processing system  10  (shown in  FIG. 1 ), for example chamber lid  42  enclosing the second wafer handler module  40 , eliminating the need to stow such structures in situ, e.g., within the workspace  24 , during removal and/or replacement of the second wafer handler module  40 . 
     With reference to  FIG. 12 , a method  200  of removing and replacing a module in a semiconductor processing system, e.g., the wafer handler module  16  (shown in  FIG. 5 ), is shown. As shown with box  202 , the method  200  includes moving a gate of a gate/barrier assembly to a closed position, e.g., the gate  102  (shown in  FIG. 3 ) to the closed position  140  (shown in  FIG. 2 ). The method  200  also includes moving a barrier of the gate/barrier assembly to a guard position, e.g., the barrier  110  (shown in  FIG. 2 ) to the guard position  164  (shown in  FIG. 5 ), as shown with box  204 . It is contemplated that the gate may be fixed to the barrier once in the closed position using a latch member, e.g., the latch member  114  (shown in  FIG. 3 ), as shown with box  206 . It is also contemplated that gate may be moved to the closed position and/or fixed to the barrier while an elevated workspace of the semiconductor processing system, e.g., the elevated workspace  24  (shown in  FIG. 2 ), is occupied by a technician, as shown with box  208 . 
     As shown with box  208 , a module, e.g., the wafer handler module  16  (shown in  FIG. 5 ), is next hoisted from the semiconductor processing system at an inboard hoisting location, e.g., the inboard hoisting location  34 . Hoisting the module may be accomplished by moving a trolley-mounted hoist to the inboard hoisting location, e.g., the trolley-mounted hoist  32 , removing covers from the wafer handling chamber housing the module, e.g., from the wafer handling chamber  14  (shown in  FIG. 1 ). Hoisting may be accomplished while by a technician occupying the elevated workspace, such as by manipulating a crank operably connected to the hoist. 
     In certain examples, hoisting the wafer handler module may include removing a chamber lid, e.g., the chamber lid  42  (shown in  FIG. 11 ), from the semiconductor processing system. The gate may then be moved to the open position and folded. Folding may be accomplished by moving an outboard portion of the gate, e.g., from the outboard position  308  (shown in  FIG. 11 ) to the inboard position  310  (shown in  FIG. 11 ). Once the gate is folded, the lid may be removed from the semiconductor processing system by shifting the lid through a space occupied by the outboard portion while previously in the extended position. 
     As shown with box  212 , next, the gate of the gate/barrier assembly is moved from the closed position to an open position, e.g., the open position  138  (shown in  FIG. 6 ). In certain examples, the moving the gate to the open position may include unfixing the gate from the barrier. In accordance with certain examples, moving the gate to the open position may be accomplished by a technician occupying the elevated workspace. In such examples the barrier provides fall protection to the technical while the technician unfixes the gate from the barrier and/or moves the gate from the closed position to the open position. The module is thereafter transferred from the inboard hoisting location to an inboard intermediate location adjacent to the passthrough, e.g., the inboard intermediate location  38  (shown  FIG. 6 ), as shown with box  214 . It is contemplated that the transfer be accomplished by a technician occupying the elevated workspace, and that the barrier provide fall protection to the technician during the transfer. 
     As shown with box  216 , the barrier is next moved from the guard position  164  to a guide position, e.g., the guide position  166  shown in  FIG. 7 ). It is contemplated that the barrier be moved to the guide position by pivoting a second post of the gate/barrier assembly, e.g., the second post  112  (shown in  FIG. 3 ), about a second post axis, e.g., the second post axis  156  (shown in  FIG. 3 ), and while seated in a second bracket, e.g., the second bracket  118  (shown in  FIG. 3 ). Pivoting second post pivots the barrier about the second post axis. Advantageously, as the barrier is fixed relative to the second post, the barrier may be moved from the guard position to the guide position from the floor, limiting (or eliminating) risk of fall through the passthrough once barrier moves from the guard position. In certain examples, the barrier is moved from the guard position to the guide position while the elevated workspace is unoccupied, as shown with box  218 . 
     As shown with box  220 , the module is next transferred through the passthrough to an outboard hoisting location, e.g., the outboard hoisting location  36  (shown in  FIG. 2 ), from the inboard intermediate location. As the module traverses the passthrough the gate moves automatically from the open position to the closed position, as shown with box  222 , e.g., by operation of a biasing member configured to urge the gate toward the closed position, e.g., the biasing member  108  (shown in  FIG. 4 ). In certain examples, the elevated workspace may by unoccupied as the module traverses the passthrough, e.g., by employment of a lanyard attached to the trolley-mounted hoist and accessible by a technician positioned on the floor adjacent the passthrough. The module is thereafter lowered from the semiconductor processing system at the outboard hoisting location, e.g., by operation of the crank operably connected to the trolley-mounted hoist, as shown with box  222 . In certain examples, lowering may be accomplished by a technician occupying the elevated workspace, fall protection provided by prior automatic movement of the gate to the closed position, as shown with box  224 . 
     The particular implementations shown and described are illustrative of the present disclosure and its best mode and are not intended to otherwise limit the scope of the aspects and implementations in any way. Indeed, for the sake of brevity, conventional manufacturing, connection, preparation, and other functional aspects of the system may not be described in detail. Furthermore, the connecting lines shown in the various figures are intended to represent exemplary functional relationships and/or physical couplings between the various elements. Many alternative or additional functional relationship or physical connections may be present in the practical system, and/or may be absent in some embodiments. 
     It is to be understood that the configurations and/or approaches described herein are exemplary in nature, and that these specific embodiments or examples are not to be considered in a limiting sense, because numerous variations are possible. The specific routines or methods described herein may represent one or more of any number of processing strategies. Thus, the various acts illustrated may be performed in the sequence illustrated, in other sequences, or omitted in some cases. 
     The subject matter of the present disclosure includes all novel and nonobvious combinations and subcombinations of the various processes, systems, and configurations, and other features, functions, acts, and/or properties disclosed herein, as well as any and all equivalents thereof. 
     ELEMENT LISTING 
     
         
         
           
               10  Semiconductor Processing System 
               12  Floor 
               14  Wafer handling chamber 
               16  Wafer Handler Module 
               18  First Processing Module 
               20  Second Processing Module 
               22  Gate Valve 
               24  Workspace 
               26  Passthrough 
               28  Staircase 
               30  Rail 
               32  Trolley-Mounted Hoist 
               34  Inboard Hoisting Location 
               36  Outboard Hoisting Location 
               38  Inboard Intermediate Location 
               40  Second Wafer Handler Module 
               42  Chamber Lid 
               100  Gate/Barrier Assembly 
               102  Gate 
               104  First Post 
               106  Hinge 
               108  Biasing Member 
               110  Barrier 
               112  Second Post 
               114  Latch Element 
               116  First Bracket 
               118  Second Bracket 
               120  Plurality of First Post Fasteners 
               122  Plurality of Second Post Fasteners 
               124  First Post Lower Portion 
               126  First Post Upper Portion 
               128  First Post Flange 
               130  First Post Axis 
               132  First Post Threaded Apertures 
               134  First Bracket Socket 
               136  First Bracket Fastener Apertures 
               138  Open Position (gate) 
               140  Closed Position (gate) 
               142  Gate Toprail 
               144  Gate Midrail 
               146  Gate First Vertical Member 
               148  Gate Second Vertical Member 
               150  Second Post Lower Portion 
               152  Second Post Upper Portion 
               154  Second Post Flange 
               156  Second Post Axis 
               158  Second Post Threaded Apertures 
               160  Second Bracket Socket 
               162  Second Bracket Fastener Apertures 
               164  Guard Position (Barrier) 
               166  Guide Position (Barrier) 
               168  Barrier Toprail 
               170  Barrier Midrail 
               172  Barrier Vertical Member 
               174  Catch Mechanism 
               176  Intermediate Position 
               200  Method 
               202  Box 
               204  Box 
               206  Box 
               208  Box 
               210  Box 
               212  Box 
               214  Box 
               216  Box 
               218  Box 
               220  Box 
               222  Box 
               300  Gate/Barrier Assembly 
               302  Gate 
               304  Inboard Portion 
               306  Outboard Portion 
               308  Extended Position 
               310  Folded Position