Patent Publication Number: US-2023134774-A1

Title: Storage shelf

Description:
TECHNICAL FIELD 
     This disclosure relates to a storage shelf. 
     BACKGROUND 
     Storage shelves are known that store containers such as reticle pods or Front Opening Unified Pods (FOUPs) in which items to be stored such as semiconductor wafers or glass substrates are stored. Such storage shelves may be provided with a storage shelf including a purging facility configured to supply purge gas such as inert gas or clean dry air to containers to maintain the cleanliness of the items to be stored. For example, Japanese Unexamined Patent Publication No. 2015-533026 discloses a shelf module including three shelves, in each of which a supply nozzle configured to supply purge gas is disposed. Each of a plurality of the shelf modules is configured to be supplied with the purge gas through a sub pipe branched from a main pipe. 
     In such storage shelves, components that are provided in a shelf module (e.g., a mass flow controller and a supply nozzle) may be replaced, or the shelf module itself may be replaced. Those replacements are collectively referred to simply as “shelf module replacement”. In this instance, an operator closes a valve leading to a purge gas supply source to shut off distribution of purge gas flowing in the main pipe, and then removes the sub pipe from a branch. After removing the sub pipe, the operator seals a removal portion to prevent impurities from entering the main pipe from the removal portion. 
     Furthermore, after replacement work of a component is completed, it is necessary to allow purge gas to flow for a while to discharge impurities that may have been mixed in from the removal portion during the replacement (aging). In this instance, the impurities may be discharged not only from a replaced shelf module but also from a supply nozzle of another shelf module, and thus the operator needs to perform a task of removing a container placed on the other shelf module. Thus, in the above-described conventional devices, the operator has a heavy workload when replacing components that are provided in the shelf modules. 
     Therefore, it could be helpful to provide a storage shelf that can reduce the workload the operator has when replacing components that are provided in the shelf module. 
     SUMMARY 
     I thus provide a storage shelf including: a main frame; a plurality of shelf modules each having a base plate detachably provided on the main frame, and a supply nozzle provided on the base plate; a main pipe through which purge gas supplied from a supply source flows, and a first branch that is provided in the main pipe and branches a flow path from the main pipe, in which the shelf modules are each provided with a mass flow controller configured to adjust the flow rate of the purge gas supplied to the supply nozzle, the first branch is connected to a module pipe via an open/close valve for opening/closing the flow path, and the mass flow controller is connected to the module pipe. 
     In a storage shelf with this configuration, when replacing any one of the shelf modules, the operator does not need to shut off purge gas flowing through the main pipe or seal a removal portion, but only needs to remove the module pipe from the open/close valve after performing a simple task of closing the open/close valve. In addition, the storage shelf with this configuration prevents foreign matter from entering the main pipe when the open/close valve is closed before the module pipe is removed. Therefore, the operator does not need to perform aging for the main pipe, which was performed in the conventional storage shelf described above, but only needs to perform aging for the module pipe. This means that the operator does not need to remove containers disposed in other shelf modules during the aging, and after connecting the module pipe, but only needs to open the open/close valve and leave it open for a while. Thus, the storage shelf with this configuration can reduce the workload the operator has when replacing the components that are provided in the shelf modules. 
     The shelf module may be provided with a plurality of the supply nozzles and a plurality of the mass flow controllers corresponding to the respective supply nozzles, the storage shelf may further include a second branch that is provided in the module pipe and branches the flow path from the module pipe, and each of the mass flow controllers may be connected to the module pipe via the second branch. 
     In this configuration, even when each of the shelf modules is provided with the supply nozzles and the mass flow controllers, the operator only needs to disconnect the module pipe from the open/close valve after performing the simple task of closing the open/close valve, and after connecting the module pipe, only needs to open the open/close valve to simply leave it open for a while. Thus, the storage shelf with this configuration can reduce the workload the operator has when replacing the components that are provided in the shelf modules. 
     The module pipe and/or the open/close valve may be supported by the main frame. In this configuration, the operator can easily remove only the shelf module because the module pipe and/or the open/close valve remains in the main frame after removing the connection between the module pipe and the open/close valve. 
     The main frame may be a suspended member that is suspended from a ceiling or from a member fixed to the ceiling and be arranged in one direction, the base plate may be bridged over the main frame arranged in the one direction, and the module pipe and/or the open/close valve may be supported by a straddle member that is a different member from the base plate and that is bridged over the main frame arranged in the one direction. In this configuration, the operator can easily remove only the shelf module because the module pipe and/or the open/close valve remains in the main frame after removing the connection between the module pipe and the open/close valve. 
     The storage shelf may further include: a main wiring that is connected to a main controller or a power supply; a module wiring that is connected to the mass flow controller or the supply nozzle provided in the shelf module and that is connected to a detection sensor configured to detect a container; and a third branch that is provided in the main wiring, electrically branches from the main wiring, and detachably connects the module wiring. In this configuration, the operator can easily remove the shelf module by a simple task of removing the module wiring from the third branch. 
     It is thus possible to reduce the workload the operator has when replacing the components that are provided in the shelf module. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a perspective view illustrating a storage shelf according to one example. 
         FIG.  2    is a configuration schematic diagram of shelf modules included in the storage shelf in  FIG.  1   . 
         FIG.  3    is a perspective view illustrating the shelf module bridged over the main unit. 
         FIG.  4    is a perspective view illustrating a state in which the shelf module bridged over the main unit is removed. 
     
    
    
     REFERENCE SIGNS LIST 
     
         
           1  Storage shelf 
           10  Main frame 
           18  Fall prevention fence (straddle member) 
           30  First shelf module 
           31  First shelf frame 
           33  First shelf plate 
           40  Second shelf module 
           41  Second shelf frame (base plate) 
           43  Second shelf plate 
           50  Purging facility 
           51  Supply nozzle 
           55  MFC (mass flow controller) 
           59  Detection sensor 
           60  Purge gas supply facility 
           61  Main pipe 
           62  First branch 
           62 A Relay pipe 
           63  Module pipe 
           64  Open/close valve 
           65  Second branch 
           70  Wiring facility 
           71  Main wiring 
           72  Third branch 
           73  Module wiring 
         F Container 
       
    
     DETAILED DESCRIPTION 
     One suitable example of my storage shelf will be described in detail below with reference to the drawings. Like or equivalent elements are designated by like reference signs in the description of the drawings, and duplicate description is omitted. Terms “X-direction,” “Y-direction,” and “Z-direction” are for convenience based on illustrated directions. In  FIG.  1   , a purge gas supply facility  60  and a wiring facility  70  are omitted. 
     A storage shelf  1  illustrated in  FIG.  1    is disposed along a track  5  of an overhead traveling car  3  that constitutes a semiconductor transfer system in a semiconductor manufacturing plant, for example. The storage shelf  1  temporarily stores a container F such as FOUPs or reticle pods in which items to be stored such as semiconductor wafers or glass substrates are stored. The storage shelf  1  includes a main frame  10 , first shelf modules  30 , second shelf modules (shelf modules)  40 , the purge gas supply facility  60  (see  FIG.  2   ), and the wiring facility  70  (see  FIG.  4   ). 
     As illustrated in  FIGS.  1  and  3   , the main frame  10  is a member that suspends the first shelf module  30  and the second shelf module  40  from a ceiling. A plurality of the main frames  10  are arranged at equal intervals along the extension direction (X direction) of the track  5 . 
     The main frame  10  has a pair of first suspending sections  11 ,  11 , a first shelf support  13 , a first connection  15 , a pair of second suspending sections  12 ,  12 , second shelf supports  14 , second connections  16 , and fall prevention fences  18 . 
     The pair of first suspending sections  11 ,  11  are suspension members that extend from a fixed portion such as the ceiling. The first shelf support  13  connects lower ends of the pair of first suspending sections  11 ,  11 . The first shelf support  13  extends along a short direction (Y direction) of the first shelf module  30  and supports the first shelf module  30  from below. The first connection  15  is connected at both ends thereof to the pair of first suspending sections  11 ,  11  and extends parallel (in the Y direction) to the first shelf support  13 . 
     The pair of second suspending sections  12 ,  12  are suspension members that extend from a fixed portion such as the ceiling. The pair of second suspending sections  12 ,  12  are disposed to sandwich the pair of first suspending sections  11 ,  11  in the opposite direction of the first suspending sections  11 ,  11 . The second shelf support  14  connects one of the pair of first suspending sections  11 ,  11  to a lower end of one of the pair of second suspending sections  12 ,  12 . The second shelf support  14  extends along the short direction (Y direction) of the second shelf module  40  and supports the second shelf module  40  from below. The second connection  16  is connected to the first suspending section  11  at one end thereof and to the second suspending section  12  at the other end thereof, and extends parallel (Y direction) to the second shelf support  14 . 
     The fall prevention fence  18  is a flat, straddle member hung between adjacent ones of the first suspending sections  11 ,  11  or between adjacent ones of the second suspending sections  12 ,  12 . The fall prevention fences  18  are disposed to sandwich the container F placed on the first shelf module  30  or the second shelf module  40  from sides of the container F (Y direction). In other words, the fall prevention fences  18  are disposed to prevent the container F placed on the first shelf module  30  or the second shelf module  40  from falling from the first shelf module  30  or the second shelf module  40 . 
     The first shelf module  30  is a member on which the container F is placed. The first shelf module  30  is a unit that does not have any purge function, i.e., a unit that does not have any function to supply gas to the container F to be placed on the first shelf module  30 . The first shelf module  30  is hung between adjacent ones of the first shelf supports  13 ,  13  or between adjacent ones of the second shelf supports  14 ,  14 . 
     The first shelf module  30  has a first shelf frame  31  and a first shelf plate  33 . The first shelf frame  31  is hung between adjacent ones of the first shelf supports  13 ,  13  or between adjacent ones of the second shelf supports  14 ,  14  in the X direction. The first shelf frame  31  is a substantially rectangular plate-shaped member in plan view from the Z direction. The first shelf frame  31  is fixed to the first shelf support  13  or the second shelf support  14  by screws inserted from below into insertion holes in the first shelf support  13  or the second shelf support  14 . Bolts and nuts may be used instead of the screws. 
     The first shelf plate  33  is supported on an upper surface of the first shelf frame  31  via an elastic body  37 . The first shelf plate  33  is a substantially rectangular plate-shaped member in plan view from the Z direction. Examples of materials for the elastic body  37  include rubber material, silicone gel material, urethane gel, and a metal spring. The first shelf plate  33  has a mounting surface on which the container F is placed, and the mounting surface is provided with pins  35 . Each of the pins  35  protrudes upward from the mounting surface of the first shelf plate  33 . The pin  35  is disposed in a position corresponding to a positioning groove (not illustrated) on a bottom of the container F. 
     As illustrated in  FIGS.  1  to  3   , the second shelf module  40  is a member on which the container F is placed. The second shelf module  40  is a unit with a purge function, i.e., a unit that supplies gas to the container F to be placed on the second shelf module  40 . Examples of the gas include nitrogen gas, dry air and the like. The second shelf module  40  is hung between adjacent ones of the second shelf supports  14 ,  14 . 
     The second shelf module  40  has a second shelf frame (base plate)  41 , a second shelf plate  43 , and a purging facility  50 . The second shelf frame  41  is hung between adjacent ones of the second shelf supports  14 ,  14  in the X direction. The second shelf frame  41  is a substantially rectangular plate-shaped member in plan view from the Z direction. 
     The second shelf plate  43  is supported on the upper surface of the second shelf frame  41  via an elastic body  47 . Examples of materials for the elastic body  47  include rubber material, silicone gel material, urethane gel, and a metal spring. The second shelf plate  43  is a substantially rectangular plate-shaped member in plan view from the Z direction. The two second shelf plates  43  are arranged along the X direction on the second shelf frame  41 . That is, the second shelf module  40  has a plurality of supply nozzles  51  and a plurality of mass flow controllers (MFCs)  55 . 
     The second shelf plate  43  has a mounting surface on which the container F is placed, and three pins  45  are provided for the single mounting surface. Each of the pins  45  protrudes upward from the mounting surface of the second shelf plate  43 . The pin  45  is disposed in a position corresponding to a positioning groove (not illustrated) on the bottom of the container F. 
     The purging facility  50  has the supply nozzle  51 , a first pipe  52 , a filter section  53 , a second pipe  54 , the MFC  55 , a third pipe  56 , and a detection sensor  59 . 
     The supply nozzle  51  is a nozzle that supplies gas to the interior of the container F. The supply nozzle  51  protrudes upward from the mounting surface of the second shelf plate  43  and is connected to an introduction hole on the bottom of the container F when the container F is placed on the supply nozzle  51 . The first pipe  52  is a tubular member that connects the supply nozzle  51  to the filter section  53 . The filter section  53  is a member housing a filter that removes foreign matter contained in gas that passes through the filter section  53 , removing foreign matter contained in gas supplied from a supply source of the gas through the main pipe  61 . The filter section  53  is fixed to the second shelf frame  41  by a suitable member. The second pipe  54  is a tubular member that connects the filter section  53  to the MFC  55 . 
     The MFC  55  is a device that measures a flow rate of the gas supplied from the main pipe  61  and controls the flow rate. The MFC  55  is controlled by the main controller, which is not illustrated. The MFC  55  is provided on each of the second shelf plates  43 . The MFC  55  is connected to a main wiring  71 , which is connected to the main controller via a module wiring  73 . 
     The main controller controls the MFC  55  to supply a predetermined flow rate of the gas to the container F when the container F is detected by the detection sensor  59 , and controls the MFC  55  not to supply the gas to the container F when the container F is not detected by the detection sensor  59 . The MFC  55  is fixed to an underside of the second shelf frame  41  by a suitable method. 
     The third pipe  56  is a tubular member that connects the MFC  55  to a second branch  65 . An end of the third pipe  56  connected to the second branch  65  is provided with a pipe connector  65 A that enables connection to the second branch  65 , which is described in detail later. 
     The detection sensor  59  detects whether the container F is placed on the second shelf plate  43 . The detection sensor  59  is provided on the mounting surface of the second shelf plate  43 . The detection sensor  59  is controlled by the main controller, which is not illustrated. The detection sensor  59  is connected to the main wiring  71 , which is connected to the main controller via the module wiring  73 . 
     As illustrated in  FIGS.  2  and  3   , the purge gas supply facility  60  has the main pipe  61 , a first branch  62 , a relay pipe  62 A, a module pipe  63 , an open/close valve  64 , and the second branch  65 . 
     The main pipe  61  is connected to the supply source of the gas to be supplied to the purging facility  50 . The main pipe  61  is a tubular member formed from metal such as stainless steel, or from resin such as fluorocarbon resin. The main pipe  61  is attached, via a mounting member  18 A, to the fall prevention fence  18 , which is hung between adjacent ones of the second suspending sections  12 ,  12 . 
     The first branch  62  is provided in the main pipe  61  to branch the flow path from the main pipe  61 . In this example, the first branches  62  are provided, the number of which corresponds to the number of the second shelf modules  40  with the purging facilities  50 . One end of the relay pipe  62 A is connected to the first branch  62 . The other end of the relay pipe  62 A is connected to the module pipe  63  via the open/close valve  64 . The relay pipe  62 A relays the purge gas flowing in the main pipe  61  to the module pipe  63 . 
     The open/close valve  64  opens and closes the flow path from the relay pipe  62 A to the module pipe  63 . In other words, the module pipe  63  is connected to the first branch  62  via the open/close valve  64  that opens and closes the flow path. The module pipe  63  and the open/close valve  64  are supported by the fall prevention fence  18 , which is hung between the adjacent ones of the second suspending sections  12 ,  12 , via a bracket  18 B. 
     The second branch  65  is provided in the module pipe  63  to branch the flow path from the module pipe  63 . As described above, the second shelf module  40  is provided with the plurality of MFCs  55 . Each of the MFCs  55  is connected to the module pipe  63  via the second branch  65 . The end of the second branch  65 , which is disposed at the most downstream section in the module pipe  63 , is sealed so that the purge gas flows only to the MFC  55 . In this example, the module pipe  63  is provided with the second branches  65 , the number of which corresponds to the number of the MFCs  55 . Each of the MFCs  55  is connected to the second branch  65  via the third pipe  56 . 
     The above-described example describes that the second branches  65  are provided, the number of which corresponds to the number of MFCs  55 . However, the second branches  65  the number of which is one less than the number of MFCs  55  may be disposed. In this example, the second branch  65 , disposed at the most downstream section in the module pipe  63 , is connected to the two MFCs  55  via the two third pipes  56 . 
     As illustrated in  FIG.  4   , the wiring facility  70  has the main wiring  71 , a third branch  72 , and the module wiring  73 . 
     The main wiring  71  is connected to the main controller that intensively controls the purging facilities  50 . The main wiring  71  is supported by the fall prevention fence  18  hung between adjacent ones of the second suspending sections  12 ,  12 , via the bracket  18 B. The main controller may be fixed to part of the storage shelf  1 , for example, or may be provided away from the storage shelf  1  via a relay device or the like. 
     The third branch  72  is provided in the main wiring  71 , electrically branches from the main wiring  71 , and detachably connects the module wiring  73 . In this example, the third branches  72  are provided, the number of which is the same as the number of MFCs  55  (or the detection sensors  59 ) provided in the second shelf module  40 . Each of the MFCs  55  (or the detection sensors  59 ) is connected to the module wiring  73  via the third branch  72 . 
     The module wiring  73  connects the third branch  72  to the MFC  55  and also connects the third branch  72  to the detection sensor  59 . The module wiring  73  is connected to the third branch  72  of the main wiring  71 . At the end of the module wiring  73  that is connected to the third branch  72 , a wiring connector  73 A is provided that enables connection to the third branch  72 . The main wiring  71  and the module wiring  73  have a function not only as communication lines for exchanging information, but also as power lines for exchanging power. 
     Next, a procedure for removing the second shelf module  40  from the main frame  10  is described. The operator first closes the open/close valve  64  illustrated in  FIGS.  2  and  3   . The operator then releases the bolts that fasten the second shelf frame  41 , which is bridged over the second shelf support  14 , and the second shelf support  14 . The operator then removes the module pipe  63  from the open/close valve  64  or removes the third pipe  56  from the second branch  65 . This completes a process of removing the second shelf module  40  from the main frame  10 . 
     Next, the procedure for attaching the second shelf module  40  to the main frame  10  will be described. The operator bridges the second shelf module  40  to the second shelf support  14 , and connects the module pipe  63  to the open/close valve  64  or connects the third pipe  56  to the second branch  65 . Next, the operator fastens the second shelf frame  41  to the second shelf support  14  with the bolts. The operator then opens the open/close valve  64  and leaves it open for a while. This completes the aging of the second shelf module  40  that has been replaced. In other words, installation of the second shelf module  40  on the main frame  10  is completed. 
     Functional effects of the storage shelf  1  according to the above-described example will be described. In the storage shelf  1  of the above-described example, when replacing the second shelf module  40 , the operator does not need to shut off the purge gas flowing through the main pipe  61  or seal the removal portion (in this example, the open/close valve  64  from which the module pipe  63  is removed or the second branch  65  from which the third pipe  56  is removed), but only needs to remove the module pipe  63  from the open/close valve  64  or remove the third pipe  56  from the second branch  65  after performing a simple task of closing the open/close valve  64 . Moreover, in the storage shelf  1  with this configuration, since the open/close valve  64  is closed to prevent foreign matter from entering the main pipe  61 , the operator does not need to perform aging for the main pipe  61 , which is performed in the above-described conventional storage shelf, but only needs to perform aging for the module pipe  63 . This means that the operator does not need to remove the containers F disposed in the other second shelf module  40  during the aging, and after connecting the module pipe  63 , only needs to open the open/close valve  64  and leave it open for a while. Thus, the storage shelf  1  with this configuration can reduce the workload the operator has when replacing the second shelf module  40  or the components that are provided in the second shelf module  40  (e.g., the supply nozzle  51  or the MFC  55  or the like). 
     In the configuration of the storage shelf  1  of the above-described example, as illustrated in  FIG.  2   , even when each of the second shelf modules  40  is provided with a plurality of the supply nozzles  51  and the MFCs  55 , the operator, after performing the simple task of closing the open/close valve  64 , only needs to remove the module pipe  63  from the open/close valve  64  or remove the third pipe  56  from the second branch  65 , and after connecting the module pipe  63 , the operator only needs to open the open/close valve  64  to leave it open for a while. Thus, the storage shelf  1  with this configuration can reduce the workload the operator has when replacing the second shelf module  40  or the components that are provided in the second shelf module  40 . 
     In the above-described configuration of the storage shelf  1 , as illustrated in  FIG.  3   , the module pipe  63  and the open/close valve  64  are supported by the fall prevention fence  18 , which is hung between the adjacent ones of the second suspending sections  12 ,  12  of the main frame  10 , via the bracket  18 B. In this configuration, after disconnecting the connection between the module pipe  63  and the open/close valve  64 , the open/close valve  64  remains on the bracket  18 B provided on the fall prevention fence  18  of the main frame  10 , and thus the operator can easily remove only the second shelf module  40 . Moreover, in this configuration, after disconnecting the connection between the second branch  65  and the third pipe  56 , the open/close valve  64  and the module pipe  63  remain on the bracket  18 B provided on the fall prevention fence  18  of the main frame  10 , and thus the operator can easily remove only the second shelf module  40 . 
     In the configuration of the storage shelf  1  of the above-described example, the operator can easily remove the second shelf module  40  by a simple task of removing the module wiring  73  from the third branch  72 . 
     Although one example has been described above, my storage shelves are not necessarily limited to the above-described example, and various modifications may be made without departing from the scope of this disclosure. 
     The above-described example describes that the two second shelf plates  43  (i.e., a place to place the container F where the supply nozzle  51  and the MFC  55  are provided) are provided on the main frame  10  via the second shelf frame  41 . However, the main frame  10  may have a configuration in which only the single second shelf plate  43  is provided on the main frame  10  via the second shelf frame  41 . In a configuration according to this modification, it is not necessary to provide the second branch  65  in the module pipe  63 , and the module pipe  63  may be directly connected to the MFC  55 . As in the above-described example, the single second branch  65  may be provided in the module pipe  63  to connect one of the branches to the MFC  55  and the other of the branches may be sealed. 
     In the above-described example and modifications, although selected configurations are described in which each of the two second shelf plates  43  is provided with the supply nozzles  51  and the MFC  55 , the purging facility  50  such as the supply nozzle  51  and the MFC  55  may be provided directly on the second shelf frame  41 . 
     In the above-described example and modifications, although the configuration is described in which the second shelf frame  41  is bridged over the main frame  10 , the second shelf plate  43  may be removed from the second shelf frame  41 . Even in this configuration, the same effects as in the above-described example and modifications can be obtained. The second shelf plate  43  in this configuration functions as a base plate attached to the main frame  10  via the second shelf frame  41 . 
     In the above-described example and modifications, although a configuration is described in which the second shelf module  40  is detachably provided in the second shelf support  14  that connects the first suspending section  11  to the lower end of the second suspending section  12 , the second shelf module  40  may be detachably installed in the first shelf support  13 . 
     In the above-described example and modifications, although a configuration is described in which an upper end of each of the first suspending section  11  and the second suspending section  12  is fixed to a fixed part such as a ceiling, this disclosure is not limited thereto. For example, the respective upper ends of the first suspending section  11  and the second suspending section  12  may be fixed to a raceway or the like that allows each of the upper ends thereof to be able to slide by being unfastened. 
     In the above-described example and modifications, although a configuration is described in which the module pipe  63  and the open/close valve  64  are supported by the fall prevention fence  18  of the main frame  10 , they may be supported in a state of bridging over the first suspending section  11  or the second suspending section  12 .