Patent Publication Number: US-11031264-B2

Title: Semiconductor device manufacturing system

Description:
RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application No. 62/764,656, filed Aug. 15, 2018, titled “Semiconductor wafer processing tool,” which is incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     With advances in semiconductor technology, there has been increasing demand for higher storage capacity, faster processing systems, higher performance, and lower costs. To meet these demands, the semiconductor industry continues to scale down the dimensions of semiconductor devices. Such scaling down has increased the complexity of semiconductor device manufacturing systems and the demands for increased throughput of these systems. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying figures. It is noted that, in accordance with the common practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of illustration and discussion. 
         FIG. 1A  is a plan view of a semiconductor device manufacturing system, in accordance with some embodiments. 
         FIG. 1B  is an enlarged view of a section of  FIG. 1A , in accordance with some embodiments. 
         FIG. 2  is a plan view of a semiconductor device manufacturing system, in accordance with some embodiments. 
         FIG. 3A  is a plan view of a semiconductor device manufacturing system, in accordance with some embodiments. 
         FIG. 3B  is a cross-sectional view of a semiconductor device manufacturing system, in accordance with some embodiments. 
         FIG. 4  is a flow chart of a method for operating a semiconductor device manufacturing system, in accordance with some embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     The following disclosure provides different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the formation of a first feature over a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features are disposed between the first and second features, such that the first and second features are not in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition does not in itself dictate a relationship between the various embodiments and/or configurations discussed. 
     Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly. 
     The term “nominal” as used herein refers to a desired, or target, value of a characteristic or parameter for a component or a process operation, set during the design phase of a product or a process, together with a range of values above and/or below the desired value. The range of values is typically due to slight variations in manufacturing processes or tolerances. 
     The term “substantially” as used herein indicates the value of a given quantity varies by, for example, ±5% of the value. 
     The term “about” as used herein indicates the value of a given quantity that can vary based on a particular technology node associated with the subject semiconductor device. Based on the particular technology node, the term “about” can indicate a value of a given quantity that varies within, for example, 5-30% of the value (e.g., ±5%, ±10%, ±20%, or ±30% of the value). 
     Semiconductor substrates (e.g., semiconductor wafers) are subjected to different device manufacturing processes (e.g., wet etching, dry etching, ashing, stripping, metal plating, epitaxy, and/or chemical mechanical polishing) in different processing chambers of processing modules of semiconductor device manufacturing systems during the fabrication of semiconductor devices. The different processing modules can be arranged in a cluster around a central, automated handling unit. Such clusters of processing modules are often referred as cluster tools. The central automated handling unit can include transfer modules that can be configured to transfer the wafers between different processing chambers and/or between processing chambers and wafer storage devices. The wafers are typically transported through transfer modules (sometimes referred as load lock modules) and temporarily stored in batches in the wafer storage devices during intervals between the different processes. 
     The processing chambers can be configured to provide a vacuum environment to conduct the different processes on the wafers. To conduct the processes in the processing chambers, the wafers are transferred from other processing chambers and/or the wafer storage devices into the processing chambers. The processing chambers are typically pumped down to a desired vacuum pressure prior to receiving the wafers. As a long pumping time (e.g. hours or days) is required to achieve the desired vacuum pressure in the processing chambers and the processing chambers can be exposed to contaminants in the atmosphere when vented, the venting of the processing chambers to atmospheric pressure are typically avoided to reduce wafer processing time, and consequently, increase the throughput of the processed wafers. 
     Rather than venting the processing chambers to atmospheric pressure to receive the semiconductor wafers, the semiconductor wafers can be transferred to the processing chambers under a vacuum environment through one or more of the transfer modules. The transfer modules can be configured to transfer and receive the wafers to and from the processing chambers under vacuum to reduce the wafer processing time and to reduce contamination in the processing chambers. 
     A transfer chamber of a transfer module can be coupled to one or more of the processing chambers with gate valves between the chambers. The transfer module can have its own pumping and venting systems. It can include a wafer holder that can hold a number of individual wafers and a mechanical transfer mechanism (e.g., a robotic arm) to move the wafers to and from the processing chambers. The wafers can be loaded into the transfer chamber from storage devices while under atmospheric pressure. The transfer chamber can then be pumped down to a vacuum pressure similar to that of the processing chamber to which the wafers are to be transferred. The gate valve between the transfer chamber and the processing chamber can then be opened and one or more of the wafers can be mechanically transferred to the processing chamber using, for example, a robotic arm of the transfer module. After the wafers are processed, they can be transferred back to the transfer chamber under vacuum in order to be placed back into the wafer storage devices and moved onto the next processing module. During this transfer process the processing chamber can be under vacuum. Thus, the transfer module allows the wafers to be transferred to and from the processing chamber without venting the processing chamber to atmospheric pressure. 
     With the increase in complexity of semiconductor device manufacturing processes, the number of manufacturing steps performed in the processing chambers also increased. As such, the frequency of access to the transfer modules also increased, where each usage of the transfer modules involves a plurality of cycles of pumping down and venting of the transfer modules. Even though the duration of pumping and venting cycles of the transfer modules are shorter compared to that of the processing chambers, the time consumed during these cycles reduces the overall throughput of the processed wafers, and consequently, reduces the throughput of the fabricated semiconductor devices. 
     The present disclosure provides example systems and methods for improving the throughput of semiconductor device manufacturing systems. In some embodiments, transfer chambers of transfer modules of the semiconductor device manufacturing systems are configured to dynamically modify the interior volumes of the transfer chambers to achieve faster pumping down and venting of the transfer chambers. In some embodiments, transfer chambers can include liners installed along their inner sidewalls. The liners can be configured to be inflatable with a gaseous medium during the pumping down and/or venting operations of the transfer module. The expansion of the volumes of the inflatable liners helps to reduce the interior volumes of the transfer chambers. As a result, the reduced volumes of the transfer chambers can be pumped down and vented faster than transfer chambers without the liners to reach the desired vacuum pressure and atmospheric pressure, respectively. In some embodiments, the time required for pumping down the transfer chambers with liners is reduced by about 5% to about 10%. In some embodiments, the time required for venting the transfer chambers with liners is reduced by about 5% to about 10%. In some embodiments, the liners can be configured to protect the robotic arms of the transfer modules from structural damages in the events of collisions with the interior of the transfer chambers during the wafer transfer operations. 
       FIG. 1A  shows a plan view of a semiconductor device manufacturing system  100 , according to some embodiments. Semiconductor device manufacturing system  100  can include processing modules  101 A- 101 B, transfer modules  103 A- 103 B, transfer tube  105 , loading ports  107 , and a control system  124 . 
     Transfer tube  105  can be configured to provide a central transfer conduit to transfer wafers between loading ports  107  and transfer modules  103 A- 103 B. In some embodiments, transfer tube  105  can include a robotic arm  113  and a wafer orientation stage  115 . Robotic arm  113  can be configured to transfer the wafers between loading ports  107 , wafer orientation stage  115 , and transfer modules  103 A- 103 B. In some embodiments, transfer tube  105  can be configured to be at atmospheric pressure or at a vacuum environment. 
     Each of loading ports  107  can accommodate a wafer storage device  108  (sometimes referred as front opening unified pod (FOUP)). Wafer storage devices  108  can be configured for temporarily storing a batch of wafers in a controlled environment during intervals between the different processes in processing modules  101 A- 101 B. Each of wafer storage devices  108  can include a purging system (not shown) to reduce humidity and contamination from environment. The purging systems can include one or more gas inlet tubes (not shown) configured to supply purging gas into wafer storage devices  108 . The purging systems can also include one or more outlets (not shown) configured to extract the purging gas from wafer storage devices  108 . 
     One or more of the batch of wafers in wafer storage devices  108  can be transferred by robotic arm  113  to wafer orientation stage  115  prior to being transferred to transfer modules  103 A and/or  103 B and subsequently to respective processing modules  101 A and/or  101 B. Wafer orientation stage  115  can be configured to adjust an orientation of each wafer toward a direction in favor of a semiconductor manufacturing process to be performed on the wafer, where an outcome of the semiconductor manufacturing process (e.g. epitaxy) depends on the wafer crystallinity. Robotic arm  113  can be further configured to transfer the oriented wafers to transfer module  103 A and/or  103 B. In some embodiments, robotic arm  113  can be configured to transfer the wafers from wafer storage devices  108  to transfer module  103 A and/or  103 B. 
     Processing modules  101 A and  101 B can include processing chambers  102 A- 102 B and gate valves  117 A- 117 B, respectively. Even though two processing modules  101 A- 101 B are shown here, system  100  can have less than or more than two processing modules similar to processing modules  101 A- 101 B. Each of processing chambers  102 A- 102 B can be configured to provide a high vacuum environment to conduct a plurality of semiconductor manufacturing processes on semiconductor wafers (not shown) that require a vacuum environment (e.g., a vacuum pressure below 10 −4  torr) to preserve, for example, the desired mean-free-path of the reacting gases, plasma and/or electrons in processing chambers  102 A- 102 B during operations. 
     In some embodiments, the plurality of semiconductor manufacturing processes can include deposition processes such as, for example, molecular beam epitaxy (MBE), chemical vapor deposition (CVD), plasma-enhanced chemical vapor deposition (PECVD), low-pressure chemical vapor deposition (LPCVD), electrochemical deposition (ECD), physical vapor deposition (PVD), atomic layer deposition (ALD), metal organic chemical vapor deposition (MOCVD), sputtering, thermal evaporation, e-beam evaporation, or other deposition processes; etching processes such as, for example, dry etching, reactive ion etching (RIE), inductively coupled plasma etching (ICP), or ion milling; thermal process such as, for example, rapid thermal annealing (RTA); microscopy such as, for example, scanning electron microscopy (SEM), and transmission electron microscopy (TEM); or any combination thereof. 
     Each of processing chambers  102 A- 102 B can include a plurality of ports for installing auxiliary manufacturing apparatus or for coupling to other vacuum chamber(s). Ports of processing chambers  102 A- 102 B can be sealed during operation with vacuum flanges equipped with knife edge or o-ring to ensure maintenance of vacuum pressure level of the processing chamber. 
     Transfer modules  103 A- 103 B can include transfer chambers  112 A- 112 B, robotic arms  111 A- 111 B, wafer stations  114 A- 114 B, and gate valves  119 A- 119 B, respectively. Transfer chambers  112 A- 112 B can be configured to enclose robotic arms  111 A- 111 B, and wafer stations  114 A- 114 B, respectively. Each of transfer modules  103 A- 103 B can be coupled to respective processing modules  101 A- 101 B with respective gate valves  117 A- 117 B between them. Gate valves  117 A- 117 B can be configured to isolate processing chambers  102 A- 102 B from transfer chambers  112 A- 112 B during wafer processing in processing chambers  102 A- 102 B, respectively. Gate valves  117 A- 117 B can be further configured to provide access between processing chambers  102 A- 102 B and transfer chambers  112 A- 112 B, respectively, during transfer of wafers between them. Transfer chambers  112 A- 112 B can be configured to be under a vacuum pressure similar to that of processing chambers  102 A- 102 B when gate valves  117 A- 117 B are configured to provide access between processing chambers  102 A- 102 B and transfer chambers  112 A- 112 B, respectively, so that processing chambers  102 A- 102 B can avoid venting to save time. In some embodiments, gate valves  117 A- 117 B can be configured to provide access between processing chambers  102 A- 102 B and transfer chambers  112 A- 112 B, respectively, in response to control signals (not shown) indicating that transfer chambers  112 A- 112 B are under a vacuum pressure similar to that of processing chambers  102 A- 102 B and that gate valves  119 A- 119 B are closed. 
     Even though one transfer module (e.g., transfer modules  103 A- 103 B) coupled to each processing modules  101 A- 101 B is shown here, system  100  can have a common transfer module that is shared between processing modules  101 A- 101 B or between N number of processing modules similar to processing modules  101 A- 101 B, where N can be any integer. The common transfer module can be similar to transfer modules  103 A- 103 B, but with N number of gate valves similar to gate valves  117 A- 117 B to provide access between the common transfer module and N number of processing modules, respectively. 
     In some embodiments, robotic arms  111 A- 111 B can be configured to transfer one or more wafers (not shown) between wafer stations  114 A- 114 B and processing chambers  102 A- 102 B, respectively. Wafer stations  114 A- 114 B can be temporary storage stations for wafers during transfer between processing chambers  102 A- 102 B and transfer chambers  112 A- 112 B, between transfer chambers  112 A- 112 B and transfer tube  105 , and/or between transfer chambers  112 A- 112 B and wafer storage devices  108  in loading ports  107 , respectively. Wafer stations  114 A- 114 B can be configured to hold one or more wafers waiting to be transferred to processing chambers  102 A- 102 B, transfer chambers  112 A- 112 B, transfer tube  105 , and/or wafer storage devices  108 , respectively. 
     Each of transfer modules  103 A- 103 B can be coupled to transfer tube  105  with respective gate valves  119 A- 119 B between them. Gate valves  119 A- 119 B can be configured to isolate transfer chambers  112 A- 112 B from transfer tube  105  during wafer transfer between processing chambers  102 A- 102 B and transfer chambers, respectively, since transfer tube  105  is typically under atmospheric pressure. Gate valves  119 A- 119 B can be further configured to provide access between transfer chambers  112 A- 112 B and transfer tube  105 , respectively, during transfer of wafers between them. Transfer chambers  112 A- 112 B can be configured to be under atmospheric pressure when gate valves  119 A- 119 B are configured to provide access between transfer chambers  112 A- 112 B and transfer tube  105 , respectively. 
     Transfer modules  103 A- 103 B can be configured to provide a pressure level within respective transfer chambers  112 A- 112 B that is similar to the pressure level within transfer tube  105  or respective processing chambers  102 A- 102 B based on where the wafers are scheduled to be transferred. Before transferring the wafers from transfer tube  105  to transfer chambers  112 A and/or  112 B, transfer modules  103 A and/or  103 B can be configured to vent respective transfer chambers  112 A and/or  112 B with an inert and/or purified gas (e.g. nitrogen or argon) to achieve the pressure level as in transfer tube  105 . In response to the pressure levels within transfer chambers  112 A and/or  112 B and transfer tube  105  being substantially equal to each other, respective gate valves  119 A and/or  119 B can be configured to open for allowing robotic arm  113  to transfer the wafers into respective transfer chambers  112 A and/or  112 B. 
     Transfer modules  103 A and/or  103 B can be further configured to pump down respective transfer chambers  112 A and/or  112 B with one or more vacuum pumps or other suitable means (not shown) to achieve a vacuum pressure similar to that of processing chambers  102 A and/or  102 B, respectively. In response to the vacuum pressure within processing chambers  102 A and/or  102 B and transfer chambers  112 A and/or  112 B, being substantially equal to each other, respectively, gate valves  117 A and/or  117 B can be configured to open to allow robotic arms  111 A and/or  111 B to transfer the wafers into processing chambers  102 A and/or  102 B, respectively. 
     Transfer modules  103 A and/or  103 B can also be configured to vent transfer chambers  112 A and/or  112 B, respectively, with an inert and/or purified gas (e.g. nitrogen or argon) to achieve a pressure level (e.g. atmosphere) that is substantially equal to that of transfer tube  105 . In response to the pressure levels within transfer chambers  112 A and/or  112 B and transfer tube  105  being substantially equal to each other, respective gate valves  119 A and/or  119 B can be opened to allow the transfer of wafers to transfer tube  105 , and subsequently, to one or more of the wafer storage devices  108  in loading ports  107 . 
     In some embodiments, transfer modules  103 A- 103 B can further include liners  121 A- 121 B, gas supply systems  109 A- 109 B, gas extraction systems  110 A- 110 B, gas inlet ports  120 A- 120 B, and gas outlet ports  122 A- 122 B, respectively. Liners  121 A- 121 B can be placed on one or more inner surfaces of transfer chambers  112 A- 112 B, respectively. In some embodiments, liners  121 A- 121 B can be placed on one or more inner side surfaces, inner upper surfaces (not shown), and/or inner bottom surfaces (not shown) of transfer chambers  112 A- 112 B, such that liners  121 A- 121 B do not block wafer stations  114 A- 114 B, robotic arms  111 A- 11 B, gate valves  117 A- 117 B, gate valves  119 A- 119 B, and/or other elements or openings (not shown) of transfer modules  103 A- 103 B, respectively. Liners  121 A- 121 B can be placed on side surfaces of transfer chambers  112 A- 112 B having gate valves  117 A- 117 B, gate valves  119 A- 119 B, gas inlet ports  120 A- 120 B, and gas outlet ports  122 A- 122 B, respectively, such that liners  121 A- 121 B do not block these gate valves and ports. In some embodiments, liners  121 A- 121 B can be placed on side surfaces of transfer chambers  112 A- 112 B having gate valves  117 A- 117 B and gate valves  119 A- 119 B without blocking the movement of robotic arms  111 A- 111 B and  113 , respectively, during their wafer transfer operations. In some embodiments, liners  121 A- 121 B can be placed on side surfaces of transfer chambers  112 A- 112 B having gas inlet ports  120 A- 120 B, and gas outlet ports  122 A- 122 B without blocking the supply and extraction of gas during the pumping down and venting operations of transfer modules  103 A- 103 B, respectively. 
     In some embodiments, liners  121 A- 121 B can be coupled to one or more inner side surfaces, inner upper surfaces (not shown), and/or inner bottom surfaces (not shown) of transfer chambers  112 A- 112 B, respectively with adhesive (e.g., tape, glues, polymeric compositions such as silicones, epoxies, or resins), mechanical parts (e.g., screws or clamps), other suitable coupling elements, or a combination thereof. The material of liners  121 A- 121 B can include nylon, rubber, plastic, synthetic, other suitable flexible material(s), or a combination thereof. 
     Liners  121 A- 121 B can be configured to reduce volume of respective transfer chambers  112 A- 112 B during pumping down and/or venting operations of respective transfer modules  103 A- 103 B. In some embodiments, liners  121 A- 121 B can be configured to be inflated with air or other suitable gas (e.g. nitrogen, argon, or an inert gas) to reduce volume of respective transfer chambers  112 A- 112 B during the pumping down and/or venting operations of respective transfer modules  103 A- 103 B. In some embodiments, liners  121 A- 121 B can be configured to be deflated during or after the venting operations of respective transfer modules  103 A- 103 B. Reducing the volume of transfer chambers  112 A- 112 B during their pumping down and/or venting operations helps to reduce the time period required to pump down and/or vent transfer chambers  112 A- 112 B. Such reduction in the pumping down and/or venting periods helps to reduce the wafer transfer time between transfer chambers  112 A- 112 B and processing chambers  102 A- 102 B, respectively and/or between transfer chambers  112 A- 112 B and transfer tube  105 . 
     In some embodiments, the volume of each of transfer chambers  112 A- 112 B can be reduced by about 5% to about 10% compared to transfer chambers without liners similar to liners  121 A- 121 B. In some embodiments, the pumping down period of transfer chambers  112 A- 112 B can be reduced by about 5% to about 10% compared to transfer chambers without liners similar to liners  121 A- 121 B. In some embodiments, the venting period of transfer chambers  112 A- 112 B can be reduced by about 5% to about 10% compared to transfer chambers without liners similar to liners  121 A- 121 B. In some embodiments, the wafer transfer time between transfer chambers  112 A- 112 B and processing chambers  102 A- 102 B, respectively can be reduced by about 5% to about 10% compared to transfer chambers without liners similar to liners  121 A- 121 B. 
     The inflation and deflation of liners  121 A- 121 B can be carried out by gas supply systems and gas extraction systems  109 A- 109 B and  110 A- 110 B through gas inlet ports  120 A- 120 B and gas outlet ports  122 A- 122 B, respectively. Gas inlet ports  120 A- 120 B and/or gas outlet ports  122 A- 122 B can be openings through sidewalls of respective transfer chambers  112 A- 112 B. In some embodiments, gas supply systems  109 A- 109 B and gas extraction systems  110 A- 110 B may be a combined system, respectively, and not separate system as illustrated in  FIG. 1A . In some embodiments, each of transfer modules  103 A- 103 B can have a common gas system (not shown) instead of gas supply systems and gas extraction systems  109 A- 109 B and  110 A- 110 B for supplying and extracting gas to and from respective liners  121 A- 121 B through a common gas inlet/outlet port (not shown) instead of through gas inlet ports  120 A- 120 B and gas outlet ports  122 A- 122 B, respectively. In some embodiments, each of liners  121 A- 121 B can be a single continuous liner as illustrated in  FIG. 1A  or can include two or more segments of liners (not shown). Each segment of liners can have its own gas inlet and outlet ports and gas supply and extraction systems for its inflation and deflation operations similar to liners  121 A- 121 B. The discussion of liners  121 A and/or  121 B herein applies to the segments of liners. 
     Liners  121 A- 121 B can be coupled to gas supply systems  109 A- 109 B and gas extraction systems  110 A- 110 B through gas inlet ports  120 A- 120 B and gas outlet ports  122 A- 122 B, respectively. The black dashed lines from gas supply systems  109 A- 109 B to gas inlet ports  120 A- 120 B, respectively, illustrate the gas supply lines and from gas outlet ports  122 A- 122 B to gas extraction systems  110 A- 110 B, respectively, illustrate the gas extraction lines. In some embodiments, gas supply lines and/or gas extraction lines can be coupled to liners  121 A- 121 B through gas inlet ports  120 A- 120 B and/or gas outlet ports  122 - 122 B, respectively, with mechanical couplings (illustrated in  FIG. 1B ) that can be configured to preserve vacuum seal in respective transfer chambers  112 A- 112 B. 
       FIG. 1B  illustrates an enlarged view of a portion  120 C of transfer module  103 A where liner  121 A is coupled to a gas supply line  109 C of gas supply system  109 A through gas inlet port  120 A. Liner  121 A can be coupled to gas supply line  109 C with a mechanical coupling that includes a pair of flanges  141 , an interface fitting  143 , O-rings  145 , and screws  147 . In some embodiments, one flange of the pair of flanges  141 , at least one of O-rings  145 , and at least one of screws  147  of the mechanical coupling can be located within liner  121 A. In some embodiments, interface-fitting  143  can be positioned within gas inlet port  120 A with a first portion of interface fitting  143  extending into liner  121 A and a second portion of interface-fitting  143  extending out of transfer module  103 A. The mechanical coupling can couple liner  121 A to gas supply line  109 C in such a manner that vacuum seal is preserved when transfer chamber  112 A operates under vacuum. 
     Referring back to  FIG. 1A , in some embodiments, liners  121 A and/or  121 B can be in a deflated state during transfer of wafers between transfer tube  105  and respective transfer chambers  112 A and/or  112 B. In some embodiments, liners  121 A and/or  121 B can be inflated by air or inert gas supplied by gas supply systems  109 A and/or  109 B through gas inlet ports  120 A and/or  120 B during transfer of wafers from transfer tube  105  to transfer chambers  112 A and/or  112 B, respectively. The inflation can be performed to prepare transfer chambers  112 A and/or  112 B for the pumping down operation prior to transferring the wafers into respective processing chambers  102 A and/or  102 B. Reducing the volume of transfer chambers  112 A and/or  112 B with respective inflated liners  121 A and/or  121 B can speed up the subsequent pumping down operation. In some embodiments, liners  121 A and/or  121 B can be inflated by air or inert gas supplied by gas supply systems  109 A and/or  109 B through gas inlet ports  120   a  and/or  120 B after receiving the wafers from transfer tube  105  and during the pumping down of transfer chambers  112 A and/or  112 B to vacuum pressure. 
     In some embodiments, liners  121 A and/or  121 B can remain in the inflated state if transfer chambers  112 A and/or  112 B remain under vacuum until the wafers are transferred back into transfer chambers  112 A and/or  112 B after being processed in processing chambers  102 A and/or  102 B, respectively. Subsequent to this transfer back of wafers into transfer chambers  112 A and/or  112 B, transfer chambers  112 A and/or  112 B can be vented to prepare these chambers for transferring the wafers back into transfer tube  105  at atmospheric pressure. During this venting operation, liners  121 A and/or  121 B can be deflated by extracting gas from liners  121 A and/or  121 B through gas outlet ports  122 A and/or  122 B using gas extraction systems  110 A and/or  110 B, respectively. In some embodiments, liners  121 A and/or  121 B can remain inflated during this venting operation and also during transfer of wafers from transfer chambers  112 A and/or  112 B to prevent structural damages to robotic arms  111 A and/or  111 B in the events of collisions with the interior of transfer chambers  112 A and/or  112 B, respectively. 
     Control system  124  can be coupled to gas supply systems  109 A- 109 B and gas extraction systems  110 A- 110 B. In some embodiments, control system  124  can be configured to control the operations of gas supply systems  109 A- 109 B and gas extraction systems  110 A- 110 B, and thus control the inflation and deflation of liners  121 A- 121 B, respectively. In some embodiments, control system  124  can activate and/or deactivate gas supply systems  109 A- 109 B and gas extraction systems  110 A- 110 B based on control signals (not shown). Control system  124  can be configured to prevent simultaneous activation of gas supply systems  109 A- 109 B and gas extraction systems  110 A- 110 B. The activation and/or deactivation of gas supply systems  109 A- 109 B and gas extraction systems  110 A- 110 B can include controlling the gas supply to gas inlet ports  120 A- 120 B and the operation of extraction pumps of gas extraction systems  110 A- 110 B, respectively. In some embodiments, to activate and deactivate gas supply systems  109 A- 109 B, control system  124  can provide activation and deactivation signals that open and close gas supply valves of gas supply systems  109 A- 109 B to supply and block, respectively, the flow of gas to gas inlet ports  120 A- 120 B. In some embodiments, to activate and deactivate gas extraction systems  110 A- 110 B, control system  124  can provide activation and deactivation signals that activate and deactivate the extraction pumps, and open and close valves of gas extraction systems  110 A- 110 B to allow and block, respectively, the flow of gas out of liners  121 A- 121 B through gas outlet ports  122 A- 122 B, respectively. 
     The operations of gas supply systems  109 A- 109 B and gas extraction systems  110 A- 110 B can be controlled by control system  124  based on one or more signals received by control system  124  that indicate the pressure levels of transfer chambers  112 A- 112 B, the gas pressure within liners  121 A- 121 B, the position of gate valves  117 A- 117 B and  119 A- 119 B, the operations of pumping and/or venting systems of transfer modules  103 A- 103 B for pumping and/or venting transfer chambers  112 A- 112 B, and/or the presence of wafers in transfer chambers  112 A- 112 B. 
     In some embodiments, control system  124  can provide activation signals to gas supply systems  109 A- 109 B for inflating liners  121 A and/or  121 B in response to receiving sensor signals that indicate the presence of wafers within transfer chambers  112 A- 112 B, the closed position of gate valves  117 A- 117 B and  119 A- 119 B, and/or the activation of pumping systems of transfer modules  103 A- 103 B for pumping down of respective transfer chambers  112 A- 112 B. Similarly, activation signals can be provided by control system  124  to gas extraction systems  110 A- 110 B for deflating liners  121 A and/or  121 B in response to receiving sensor signals that indicate the absence of wafers from within transfer chambers  112 A- 112 B, closed position of gate valves  117 A- 117 B and  119 A- 119 B, and/or the activation of venting systems of transfer modules  103 A- 103 B for venting of respective transfer chambers  112 A- 112 B. 
     In some embodiments, deactivation signals can be provided by control system  124  to gas supply systems  109 A- 109 B and gas extraction systems  110 A- 110 B in response to receiving a sensor signal indicating that the gas pressure within liners  121 A- 121 B is above and below a desired value, respectively. In some embodiments, deactivation signals can be provided by control system  124  to gas supply systems  109 A- 109 B and gas extraction systems  110 A- 110 B based on the duration of gas supplied to and gas extracted from liners  121 A- 121 B, respectively. 
       FIG. 2  shows a plan view of a semiconductor wafer manufacturing system  200 , according to some embodiments. The discussion of semiconductor wafer manufacturing system  100  applies to semiconductor wafer manufacturing system  200  unless mentioned otherwise. Semiconductor device manufacturing system  200  can include processing modules  101 A- 101 B, transfer modules  203 A- 203 B, transfer tube  105 , and loading ports  107 . Transfer modules  203 A- 203 B can include transfer chambers  212 A- 212 B, respectively. The discussion of elements with the same annotations in  FIGS. 1A-1B and 2  applies to each other unless mentioned otherwise. 
     The discussion of transfer modules  103 A- 103 B and transfer chambers  112 A- 112 B applies to transfer modules  203 A- 203 B and transfer chambers  212 A- 212 B unless mentioned otherwise. Each of transfer chambers  212 A- 212 B can include liners  221 A- 221 B, respectively. Each of liners  221 A- 221 B can be a permanently inflated flexible element. As such, unlike transfer chambers  112 A- 112 B, transfer chambers  212 A- 212 B does not have gas inlet ports  120 A- 120 B and gas outlet ports  122 A- 122 B for the inflation and deflation of liners  221 A- 221 B, respectively. Liners  221 A- 221 B can be inflated with air, any gas species such as nitrogen, or flakes of soft material prior to installing them within transfer chambers  212 A- 212 B, respectively. Composition of liners  221 A- 221 B can be similar to that of liners  121 A- 121 B. In some embodiments, liners  221 A- 221 B can include plastic, synthetic or any other suitable material. The placement of liners  221 A- 221 B inside transfer chambers  212 A- 212 B can be similar to that of liners  121 A- 121 B unless mentioned otherwise. In some embodiments, liners  221 A- 221 B can be coupled to one or more inner surfaces of transfer chambers  212 - 212 B via adhesive, tapes, or mechanical parts such as clamp. Similar to liners  121 A- 121 B, inflated liners  221 A- 221 B can reduce interior volume of transfer chambers  212 A- 212 B, and thus can reduce the pump downing and/or venting time of transfer chambers  212 A- 212 B during the wafer transfer operations. The wafer transfer operations of system  200  can be similar to that of system  100  described above with reference to  FIG. 1A . 
       FIG. 3A  shows a plan view of a semiconductor wafer manufacturing system  300  and  FIG. 3B  shows a cross-sectional view of system  300  along line A-A of  FIG. 3A , according to some embodiments. The discussion of semiconductor wafer manufacturing system  100  applies to semiconductor wafer manufacturing system  300  unless mentioned otherwise. Semiconductor wafer manufacturing system  300  can include a transfer module  303  and loading ports  307 . The discussion of transfer module  103 A and loading ports  107  applies to transfer module  303  and loading ports  307 , respectively, unless mentioned otherwise. 
     Transfer module  303  can include transfer chamber  312  and robotic arm  311 . The discussion of transfer chamber  112 A and robotic arm  111 A applies to transfer chamber  312  and robotic arm  311  unless mentioned otherwise. Transfer module  303  can be coupled to loading ports  307  and one or more processing modules (not shown) similar to processing module  101 A. Transfer module  303  can be configured to provide a pressure level within transfer chamber  312  that is similar to the pressure level within loading ports  307  or processing chambers of the one or more processing modules (not shown) based on where the wafers are scheduled to be transferred. 
     Transfer module  303  can be configured to pump down transfer chambers  312  with one or more vacuum pumps or other suitable means (not shown) to achieve a vacuum pressure similar to that of processing chambers of the one or more processing modules (not shown). In response to the vacuum pressure within the processing chambers and transfer chamber  312  being substantially equal to each other, robotic arm  311  can transfer the wafers into the processing chambers. Transfer module  303  can also be configured to vent transfer chamber  312  with an inert and/or purified gas (e.g. nitrogen or argon) to achieve a pressure level (e.g. atmosphere) that is substantially equal to that of one of loading ports  307 . In response to the pressure levels within transfer chamber  312  and one of loading ports  307  being substantially equal to each other, robotic arm  311  can transfer the wafers to one or more of the wafer storage devices in one of loading ports  307 . 
     In some embodiments, transfer module  303  can further include a liner  321 , a gas supply system  309 , a gas extraction system  310 , and a control unit  324 . The discussion of liner  121 A, gas supply system  109 A, gas extraction system  110 A, and control unit  124  applies to liner  321 , gas supply system  309 , gas extraction system  310 , and control unit  324  unless mentioned otherwise. For example, the placement of liner  321  within transfer chamber  312  can be similar to that of liner  121 A. The placement of liner  321  along the inner surfaces of transfer chamber  312  is further illustrated in  FIG. 3B , which shows a cross-sectional view of transfer module  303  along line A-A of  FIG. 3A . 
     Similar to liner  121 A, liner  321  can be coupled to gas supply systems  309  and gas extraction system  310  through gas inlet port  320  and gas outlet port  322 , respectively, with mechanical couplings (not shown). The discussion of gas inlet port  120 A and gas outlet port  122 A applies to gas inlet port  320  and gas outlet port  322 , respectively. Liner  321  can be configured to reduce volume of transfer chamber  312  during pumping down and/or venting operations of transfer module  303 . In some embodiments, liner  321  can be configured to be inflated with air or other suitable gas (e.g. nitrogen, argon, or an inert gas) to reduce volume of transfer chamber  312  during the pumping down and/or venting operations of transfer module  303 . In some embodiments, liner  321  can be configured to be deflated during or after the venting operations of transfer module  303 . Reducing the volume of transfer chamber  312  during the pumping down and/or venting operations helps to reduce the time period required to pump down and/or vent transfer chamber  312 . Such reduction in the pumping down and/or venting periods helps to reduce the wafer transfer time between transfer chamber  312  and processing chambers and/or between transfer chamber  312  and loading ports  307 . 
     In some embodiments, liner  321  can be a permanently inflated liner similar to liner  221 A. In such embodiments, transfer module  303  may not have gas inlet port  320 , gas outlet port  322 , gas supply system  309 , gas extraction system  310  and control system  324 . 
       FIG. 4  is an example method  400  for operating a semiconductor wafer manufacturing system as described with reference to  FIGS. 1A-1B , according to some embodiments. This disclosure is not limited to this operational description. It is to be appreciated that additional operations may be performed. Moreover, not all operations may be needed to perform the disclosure provided herein. Further, some of the operations may be performed simultaneously, or in a different order than shown in  FIG. 4 . In some implementations, one or more other operations may be performed in addition to or in place of the presently described operations. For illustrative purposes, method  400  is described with reference to the embodiments of  FIGS. 1A-1B . However, method  400  is not limited to these embodiments. 
     In operation  410 , a semiconductor wafer is transferred from a loading port to a transfer module of the semiconductor wafer manufacturing system. For example, as described with reference to  FIG. 1A , a wafer can be transferred from loading port  107  to transfer chamber  112 A of transfer module  103 A. This wafer transfer operation can include transferring the wafer from loading port  107  to transfer tube  105  and from transfer tube  105  to transfer chamber  112 A. The wafer transfer operation between loading port  107  to transfer tube  105  can include transferring the wafer from loading port  107  by robotic arm  113  to wafer orientation stage  115 . The wafer transfer operation between transfer tube  105  and transfer chamber  112 A can include venting transfer chamber  112 A to atmospheric pressure (e.g., 760 mtorr) and transferring the oriented wafer from wafer orientation stage  115  by robotic arm  113  to transfer chamber  112 A. In some embodiments, the wafer can be placed on wafer station  114 A. 
     In referring to  FIG. 4 , in operation  420 , the transfer module is pumped down and a volume of a liner of the transfer module is adjusted. For example, as described with reference to  FIG. 1A , transfer chamber  112 A can be pumped down to a vacuum pressure level (e.g., between about 10 mtorr to about 50 mtorr) and liner  121 A can be inflated to reduce volume of transfer chamber  112 A for faster pumping down of transfer chamber  112 A. The inflating operation can be carried out by gas supply system  109 A through gas inlet port  120 A prior to or simultaneously with the pumping down operation. Liner  121 A can be inflated with air or other suitable gas (e.g. nitrogen, argon, or an inert gas). In some embodiments, liner  121 A can be inflated at a rate that is faster than a rate at which transfer chamber  112 A is pumped down. 
     In referring to  FIG. 4 , in operation  430 , the wafers are transferred from the transfer module to a processing module. For example, as described with reference to  FIG. 1A , the wafer can be transferred from transfer chamber  112 A to processing chamber  102 A of processing module  101 A. This transfer operation can include adjusting the pressure in processing chamber  102 A to be substantially similar to the pressure in transfer chamber  112 A followed by the opening of gate valve  117 A, the transfer of the wafer from transfer chamber  112 A to processing chamber  102 A using robotic arm  111 A, closing of gate valve  117 A, and pumping down the processing chamber  102 A to a vacuum pressure level (e.g., between about 1 mtorr to about 10 mtorr) suitable for processing the wafer. In some embodiments, the adjusting the pressure in processing chamber  102 A can include venting processing chamber  102 A to increase the chamber pressure from about 10 mtorr to about 50 mtorr. 
     In referring to  FIG. 4 , in operation  440 , one or more semiconductor manufacturing processes are performed on the wafer in the processing module. For example, as described with reference to  FIG. 1A , one or more semiconductor manufacturing processes can be performed on the wafer in processing chamber  102 A. The one or more semiconductor manufacturing procedures can include deposition processes such as MBE, CVD, PECVD, LPCVD, ECD, PVD, ALD, MOCVD, sputtering, thermal evaporation, e-beam evaporation, or other deposition processes; etching processes such as dry etching, RIE, ICP, and ion milling; thermal process such as RTA; and microscopy such as SEM, and TEM; or any combination thereof. In some embodiments, a high vacuum (e.g., between about 1 mtorr to about 10 mtorr) is preserved within processing chamber  102 A during the one or more manufacturing processes. 
     In referring to  FIG. 4 , in operation  450 , the processed wafer is transferred from the processing module to the transfer module. For example, as described with reference to  FIG. 1A , the processed wafer can be transferred from processing chamber  102 A to transfer chamber  112 A. This transfer operation can include adjusting the pressure in processing chamber  102 A to be substantially similar to the pressure in transfer chamber  112 A followed by the opening of gate valve  117 A, the transfer of the wafer from processing chamber  102 A to transfer chamber  112 A using robotic arm  111 A, closing of gate valve  117 A, and pumping down the processing chamber  102 A to a vacuum pressure level (e.g., between about 1 mtorr to about 10 mtorr). In some embodiments, the adjusting the pressure in processing chamber  102 A can include venting processing chamber  102 A to increase the chamber pressure from about 10 mtorr to about 50 mtorr. 
     In some embodiments, this transfer operation  450  can also include measuring pressure of transfer chamber  112 A prior to the opening of gate valve  117 A and performing operation similar to operation  420  in response to pressure of transfer chamber  112 A being different from the adjusted pressure of processing chamber  102 A. 
     In referring to  FIG. 4 , in operation  460 , the transfer module is vented. For example, as described with reference to  FIG. 1A , transfer chamber  112 A can be vented to atmospheric pressure and the processed wafer can be transferred back to one of loading ports  107  using robotic arm  113 . In some embodiments, liner  121 A can be deflated during or after venting of transfer chamber  112 A. Deflating liner  121 A can include extracting gas from liner  121 A through gas outlet port  122 A using gas extraction system  110 A. In some embodiments, liner  121 A can remain inflated during or after venting of transfer chamber  112 A. 
     The present disclosure provides example systems and methods for improving the throughput of semiconductor device manufacturing systems. In some embodiments, transfer chambers of transfer modules of the semiconductor device manufacturing systems are configured to dynamically modify the interior volumes of the transfer chambers (e.g., transfer chambers  112 A,  112 B, and/or  312 ) to achieve faster pumping down and venting of the transfer chambers. In some embodiments, transfer chambers can include liners (e.g., liners  121 A,  121 B,  221 A,  221 B, and/or  321 ) installed along their inner sidewalls. The liners can be configured to be inflatable with a gaseous medium during the pumping down and/or venting operations of the transfer module. The expansion of the volumes of the inflatable liners helps to reduce the interior volumes of the transfer chambers. As a result, the reduced volumes of the transfer chambers can be pumped down and vented faster than transfer chambers without the liners to reach the desired vacuum pressure and atmospheric pressure, respectively. In some embodiments, the time required for pumping down the transfer chambers with liners is reduced by about 5% to about 10%. In some embodiments, the time required for venting the transfer chambers with liners is reduced by about 5% to about 10%. In some embodiments, the liners can be configured to protect the robotic arms of the transfer modules from structural damages in the events of collisions with the interior of the transfer chambers during the wafer transfer operations. 
     In some embodiments, a semiconductor device manufacturing system includes a processing module and a transfer module. The processing module includes a processing chamber that is configured to process a semiconductor wafer and a gate valve that is configured to provide access to the processing chamber. The transfer module includes a transfer chamber that is coupled to the processing chamber and a liner that is coupled to an inner surface of the transfer chamber. The liner is configured to reduce a volume of the transfer chamber prior to or during a transfer chamber pressure adjustment operation of the transfer module. 
     In some embodiments, a system includes a processing module and a transfer module. The processing module includes a processing chamber that is configured to process a semiconductor wafer. The transfer module includes a transfer chamber that is coupled to the processing chamber and an inflated liner that is coupled to an inner side surface of the transfer chamber. 
     In some embodiments, a method of operating a semiconductor device manufacturing system includes transferring a semiconductor wafer into a transfer chamber of a transfer module, inflating a liner coupled to an inner surface of the transfer chamber, pumping down the transfer chamber to a vacuum pressure level, and transferring the semiconductor wafer from the transfer chamber to a processing chamber of a processing module. 
     The foregoing disclosure outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.