Source: http://www.google.es/patents/US7151366?dq=flatulence
Timestamp: 2013-05-23 08:08:50
Document Index: 419434324

Matched Legal Cases: ['art.\n20', 'art.\n21', 'art.\n22', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60']

Patente US7151366 - Integrated process condition sensing wafer and data analysis system - Google PatentesB�squeda Im�genes Maps Play YouTube Noticias Gmail Drive M�s » B�squeda avanzada de patentes | Historial web | Iniciar sesi�n B�squeda avanzada de patentesPatentesA process condition measuring device and a handling system may be highly integrated with a production environment where the dimensions of the process condition measuring device are close to those of a production substrate and the handling system is similar to a substrate carrier used for production substrates....http://www.google.es/patents/US7151366?utm_source=gb-gplus-sharePatente US7151366 - Integrated process condition sensing wafer and data analysis system N�mero de publicaci�nUS7151366 B2Tipo de publicaci�nConcesi�n N�mero de solicitud10/718,269 Fecha de publicaci�n19 Dic 2006 Fecha de presentaci�n19 Nov 2003 Fecha de prioridad3 Dic 2002Tambi�n publicado comoUS7149643US20040154417US20050246127WO2004051713A2WO2004051713A3 InventoresWayne Glenn RenkenEarl JensenRoy Gordon Cesionario originalSensarray Corporation Clasificaci�n de EE.UU.324/750.2324/754.31324/762.5 Clasificaci�n internacionalH01L21/00G01R31/28 Clasificaci�n cooperativaH01L2924/15157H01L2924/16153H01L2924/3011H01L2924/01087H01L2224/48091H01L2924/3025H01L2924/16195H01L2924/16152H01L2924/15165H01L2924/15153H01L2924/19041H01L21/67253 Clasificaci�n europeaH01L21/67S8BReferenciasCitas de patentes (52)Otras citas (12) Citada por (16)Enlaces externosUSPTO Cesi�n de USPTO EspacenetIntegrated process condition sensing wafer and data analysis systemUS 7151366 B2 Resumen A process condition measuring device and a handling system may be highly integrated with a production environment where the dimensions of the process condition measuring device are close to those of a production substrate and the handling system is similar to a substrate carrier used for production substrates. Process conditions may be measured with little disturbance to the production environment. Data may be transferred from a process condition measuring device to a user with little or no human intervention.
1. A sensing apparatus for sensing conditions in target environments in a processing facility where a standard substrate is transported in a standard substrate carrier that establishes a position of the standard substrate relative to a surface of the standard substrate carrier and where the robot of at least one processing tool is calibrated to the position of the standard substrate relative to the surface of the standard substrate carrier, comprising:
a plurality of sensors attached to the substrate;
a second portion that includes:
a substrate carrier that establishes the position of the first portion relative to a surface of the substrate carrier to be the same as the position of the standard substrate relative to the surface of the standard substrate carrier;
an electronics module that communicates with the first portion, the electronics module attached to the substrate carrier; and wherein the first portion may be moved independently of the second portion.
2. The sensing apparatus of claim 1 wherein the substrate carrier is a standard substrate carrier.
3. The sensing apparatus of claim 1 wherein the position of the standard substrate relative to the surface of the standard substrate carrier is the vertical height of the standard substrate above the bottom surface of the standard substrate carrier.
4. The sensing apparatus of claim 1 further comprising:
a receiving unit attached to the substrate that receives power from the electronics module; and
a transmitting unit in the electronic module that transmits power to the receiving unit.
5. The sensing apparatus of claim 4 wherein the receiving unit is located at the center of the substrate so that when the substrate is placed in the substrate carrier the receiving unit is aligned with the transmitting unit regardless of the rotational orientation of the substrate.
6. The sensing apparatus of claim 4 wherein the receiving unit receives data from the electronics module and the transmitting unit transmits data to the receiving unit.
7. The sensing apparatus of claim 4 wherein the transmitting unit comprises an E-coil and the receiving unit comprises a conductive coil and a magnetic conductive layer.
8. The sensing apparatus of claim 1 wherein the second portion further comprises an RFID transceiver electrically connected to the electronics module so that data may be sent from the electronics module to the RFID transceiver and data may be sent from the RFID transceiver to an external receiver.
9. The sensing apparatus of claim 1 further comprising:
a pattern on at least one surface of the substrate; and
an optical reading apparatus apparatus to the substrate carrier that reads the pattern on the substrate to determine the orientation of the substrate.
10. The sensing apparatus of claim 1 wherein the second portion further comprises an alignment module that aligns the first portion relative to the substrate carrier.
11. A sensing apparatus for sensing process conditions in a processing tool that has a robot that transfers a standard substrate between a standard substrate carrier and a process chamber, comprising:
a process condition measuring device, comprising:
a handling system, comprising:
a substrate carrier that holds the process condition measuring device, the robot transferring the process condition measuring device between the substrate carrier and the process chamber; and
an electronics module attached to the substrate carrier that communicates with the process condition measuring device while the substrate carrier holds the process condition measuring device.
12. The sensing apparatus of claim 11 wherein the substrate carrier is a standard substrate carrier.
13. The sensing apparatus of claim 1 wherein the substrate carrier is a front opening unified pod (FOUP).
14. The sensing apparatus of claim 11 wherein the substrate carrier is a wafer cassette.
15. The sensing apparatus of claim 11 wherein the process condition measuring device further includes at least one battery and other components attached to the substrate and the location of the at least one battery and the other components that are attached to the substrate are configured such that the center of gravity of the substrate with the at least one battery and the other components is the same as the center of gravity of the substrate alone.
16. The sensing apparatus of claim 11 wherein the process condition measuring device further includes conductive traces connecting sensors to a CPU, at least one battery, a clock crystal and an RF inductive coil.
17. A two part apparatus for measuring process conditions within a process chamber, comprising:
a first part that includes a plurality of sensors for measuring one or more process conditions, a receiving unit that receives power and an energy storage unit attached to a substrate;
a second part that includes a housing for the first part, a power supply unit attached to the housing and a communication unit attached to the housing, the power supply unit providing power to the receiving unit of the first part and the communication unit providing communication between the first part and the second part; and
wherein the first part is housed in the second part in a first mode and is moved from the second part to the process chamber, without physical connection to the second part, in a second mode.
18. The two part apparatus of claim 17 wherein the substrate is a disk with the diameter of a silicon wafer and the housing is a wafer holder.
19. The two part apparatus of claim 18 wherein the power supply unit has an induction coil that inductively transmits power to the first part.
20. The two part apparatus of claim 19 wherein the communication unit uses the induction coil to provide communication between the first part and the second part.
21. The two part apparatus of claim 18 wherein the communication unit uses light to communicate with the first part.
22. The two part apparatus of claim 17 wherein the housing is a Standard Mechanical Interface (SMIF) box or a Front Opening Unified Pod (FOUP).
23. An apparatus for measuring conditions in a target environment, comprising:
a process condition measuring device that includes sensors to measure one or more process conditions in the target environment, the process condition measuring device further including a power supply and a first induction coil;
a handling system including a second induction coil, the handling system having a location to hold the process condition measuring device near the second induction coil, the first and second induction coils being inductively coupled when the process condition measuring device is at the location, the inductive coupling transferring both electrical power and data; and
the process condition measuring device being independently movable from the handling system to measure process conditions.
24. The apparatus of claim 23 wherein power is transferred from the handling system to the process condition measuring device through the inductive coupling and data is transferred from the process condition measuring device to the handling system through the inductive coupling.
25. The apparatus of claim 24 wherein data is also transferred from the handling system to the process condition measuring device through the inductive coupling.
CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 60/430,858 filed on Dec. 3, 2002; U.S. Provisional Patent Application No. 60/496,294 filed on Aug. 19, 2003; U.S. Provisional Patent Application No. 60/512,243 filed on Oct. 17, 2003.
Within the processing chamber a robot transports the test wafer or substrate. One example of a device incorporating a robot is manufactured by the TEL Corporation. For more information about the robot and processing chamber, please refer to U.S. Pat. No. 5,564,889 to Araki, entitled �Semiconductor Treatment System and Method for Exchanging and Treating Substrate,� which is hereby incorporated by this reference in its entirety. This application relates to U.S. Provisional Patent Application No. 60/430,858 filed on Dec. 3, 2002; U.S. Provisional Patent Application No. 60/496,294 filed on Aug. 19, 2003; U.S. Provisional Patent Application No. 60/512,243 entitled �Integrated Process Condition Sensing Wafer and Data Analysis System� by Wane Renken et al, filed on Oct. 17, 2003; and to U.S. patent application Ser. No. 10/056,906 to Renken, which are hereby incorporated by this reference in their entirety.
SUMMARY OF THE INVENTION A process condition measuring device (PCMD) is disclosed that may be delivered to a target environment, acquire a wide range of data and return to a handling system with little disruption to the target environment or the tool containing the target environment. The PCMD is designed to have similar characteristics to the substrates normally handled by the tool. The characteristics of such substrates are generally specified by industry standards. Thus, for a system designed for 300 mm silicon wafers, the PCMD has a silicon substrate and has similar physical dimensions to those of a 300 mm wafer. Components may be located within cavities in the substrate to keep the profile of the PCMD the same as, or close to that of a 300 mm wafer. Because of its dimensions and its wireless design, the PCMD may be handled by a robot as if it were a 300 mm wafer. It may undergo the process steps undergone by wafers such as etch, clean, photolithography etc. The PCMD records process conditions such as temperature, pressure and gas flow rate during processing and uploads the data when requested. Conditions during transport and storage may also be monitored and recorded.
A PCMD may have a pattern on its surface that allows its orientation to be determined. Greycode printed on the edge of a surface of a PCMD may allow the rotational orientation of the PCMD to be determined. Greycode readers may be installed in a handling system so that the orientation of the PCMD is known before it is sent on a survey and after it returns. Such a system does not require movement of the PCMD relative to the readers in order to determine orientation.
BRIEF DESCRIPTION OF THE FIGURES FIG. 1A is a plan view of Process Condition Measuring Device (�PCMD�) 100.
FIG. 2A is a perspective view of the back of Handling System (�HS�) 200.
FIG. 7 shows a PCMD 700 having four transmitters 728�731.
FIG. 9 shows various communication systems between PCMD 900, handling system 980 and software application 987.
FIG. 10 shows different examples of lids protecting components of PCMDs.
DETAILED DESCRIPTION The measurement system in one embodiment measures processing conditions in various locations of a wafer or substrate and records them in memory for later transmission or downloading of the process conditions. In another embodiment of the measurement system where a processing chamber has windows capable of data transmission, the system is additionally capable of transmitting the processing conditions in real time to a data processing device.
FIG. 1A illustrates process condition measuring device (�PCMD�) 100, an embodiment of the present invention. PCMD 100 is part of a process measurement system, the other components of which will be described later with reference to FIG. 2. PCMD 100 comprises a substrate such as a silicon wafer, glass substrate, or other substrates well known in the art. Substrate 102 (not visible in plan view) is preferably a silicon wafer and may be of any diameter but is preferably an 8, 10, or 12 inch diameter wafer.
A number of components are integrated to form PCMD 100. Sensors 124 are distributed about PCMD 100 and are, therefore, capable of detecting gradients in various processing conditions across the surface of the substrate. Sensors 124 are connected to the microprocessor 104 through conductive traces 120. Conductive traces 120 preferably comprise aluminum, but may comprise any conductive material, the formation of PCMD 100, including the conductive traces and the other components will be described later with reference to FIGS. 3 and 4. Microprocessor 104 preferably includes flash memory cells for storing the processing conditions and other instructions necessary for the operation of PCMD 100. However, the flash, or other type memory, may alternatively be part of a discrete EPROM or EEPROM rather than being an integral part of microprocessor 104. Clock crystal 132 generates a timing signal used in various operations of PCMD 100. Transmitter 128 preferably comprises a light emitting diode (LED) for transmitting data. Around transmitter 108 is a radio frequency (RF) inductive coil 108 receives data and serves to inductively charge power sources 112A and 112B. In one embodiment of the invention, transmitter 128 may also act as a transceiver and receive data as well as transmit data. Additionally, coil 108 may also act not only as a receiver, but also as a transmitter. Thus, coil 108 may serve as a receiving unit that may receive both data and power.
In the embodiment illustrated, power sources 112A and 112B are thin film lithium ion batteries that are equidistant from the center of the PCMD 100. The thin 0.25 mm thick power sources allow for a thin overall PCMD structure with a thickness of 0.70 mm, which is comparable to a production wafer and compatible with the robot arms typically used in wafer handling procedures. These power sources have previously been common to under-skin medical implants where they are similarly inductively charged. Power sources 112A and 112B are capable of continuous operation at temperatures up to roughly the melting point of lithium, around 180 degrees Centigrade. The equidistant spacing of the power sources 112A, 112B shown in FIGS. 1D and 1E, maintains the balance of PCMD 100 which is beneficial in situations where PCMD 100 may be spinning within a processing module. FIG. 1E shows the central axis 199 of PCMD 100 passing through the center of PCMD 100. Central axis 199 is perpendicular to a surface 198 of MD 100. The center of gravity of PCMD 100 lies along central axis 199. Central axis 199 is the axis of rotation when PCMD is spun in a processing module. Batteries 112A and 112B are equidistant from central axis 199 and are 180 degrees apart. Thus, where batteries 112A and 112B are of the same mass, their combined center of gravity is along central axis 199. Additionally, the other components are arranged in order to maintain as uniform a mass and thermal profile as possible. A passivation layer 116 and an optional shield layer are formed above all of the components of PCMD 100 in order to protect the components and substrate from various processing conditions. The layers that make up PCMD 100 will be described in further detail later with reference to FIGS. 3 and 4.
Coil 108 of FIG. 1 may be located within a cavity in the substrate. Coil 108 may be extremely thin so that it does not add to the overall height of the PCMD 100. For example, FIG. 5A shows a cross-section of a coil 508 during inductive charging. In this example, coil 508 includes several windings of increasing radius. However, coil 508 is only one winding in height so that the thickness of coil 508 is approximately the same as the thickness of the conductor used for the winding. Coil 508 may be located in the middle of the wafer as shown in FIG. 1A. FIG. 5A shows a similar coil 508 in a cavity 550 within the substrate 502. FIG. 5A shows the position of coil 508 with respect to an E-coil 510 located in electronics module 508. E-coil 510 maybe used to supply power to the PCMD 100 by inducing an electrical current in the windings of coil 508. E-coil 510 may also be used to transmit data to coil 508. Thus, the induced field is used to transmit both power and data to PCMD 100. E-coil 510 typically provides an RF field at a frequency of 13.56 MHz. One advantage of placing coil 508 at its axis passes through the center of the PCMD is that it may easily be aligned with an external unit such as E-coil 510 because the rotational orientation of PCMD 100 does not affect the position of the coil 508. Thus, E-coil 510 may serve as a transmitting unit that may transmit both power and data.
Amplifier 662 provides positive feedback to maintain the oscillator signal. Amplifiers available in commercially produced ICs, such as amplifier 662, are specified as working over a certain range of temperature, for example 0�85 degrees centigrade. When the temperature is higher than the specified range, conventional oscillator circuit 661 may no longer function correctly. Threshold voltages of components in the amplifier may shift which eventually causes oscillation to cease or startup to fail. When amplifier 662 is working within its specified temperature range it produces a signal with a 50% duty cycle. With increasing temperature the duty cycle increases and as the duty cycle approaches 100% conventional oscillator circuit 661 ceases to function.
Biasing circuit 670 overcomes this problem by biasing the input of amplifier 662 in order to maintain a 50% duty cycle. Counter 67l uses the input from ring oscillator 672 to determine the duty cycle. Counter 671 counts the number of clock cycles of ring oscillator 672 during the �on� phase of the output of amplifier 662. It then counts the number of clock cycles of ring oscillator 672 during the �off� phase of the output of amplifier 662. The counts are sent to the bias control unit 673 where the duty cycle is. determined. If these counts are equal then the duty cycle is 50%. If the count for the �on� phase exceeds the count for the �off� phase, then the duty cycle is greater than 50%. The frequency of ring oscillator 672 is greater than the frequency of the output of conventional oscillator circuit 661. Typically, the conventional oscillator circuit has an output frequency of about 32 kHz while the ring oscillator has an output frequency of about 400 kHz�4 MHz. Ring oscillator 672 may suffer from a change in frequency at high temperature. However, because the output for two periods are compared, the absolute value of the output over a given period does not affect the determination of duty cycle.
If the duty cycle is determined to be greater than 50% the bias control unit 673 may modify the bias input 676 to reduce the duty cycle. This may be done in a number of ways. In the example shown in FIG. 6, a series of resistors 675 of different resistances are connected between a bias voltage and bias input 676. The bias voltage used may be Vcc on the CPU chip. In this way, the voltage and current at the input of amplifier 662 may be controlled to bring the duty cycle back to 50%. Using this technique, the effective range of high temperature crystal oscillator circuit 660 may be extended from the stated upper limit of the CPU chip 604 (85 degrees centigrade) to as high as 150 degrees centigrade. This allows PCMD 100 to use standard parts in conditions that would otherwise require custom parts. As alternatives to using resistors 675, other comparable means may be used to modify impedance such that a change in bias is achieved. These alternatives include an electronic potentiometer, transistor, voltage resistor network.
Transmitter 128 shown in FIG. 1A may be used to transmit data from the PCMD. Here, transmitter 128 is an LED. This is a more energy efficient way to transmit data than using RF via coil 108. For transmission from the PCMD energy efficiency is important, whereas for transmitting data to the PCMD energy is generally not as critical so that RF may be used. In the example shown in FIG. 1A the transmitter is located at the center of the upper surface of the PCMD. Placing LED 128 in the center allows it to be more easily aligned with any external receiver because the position of LED 128 with respect to the external receiver will not vary if PCMD 100 is rotated. This may be important where PCMD 100 is rotated during a survey as occurs in some environments.
In another embodiment shown in FIG. 7, four transmitters 728�731 are located around coil 708. This example also uses LEDs as transmitters 728�731. Using multiple LEDs allows a receiving unit 777 in an electronics module 778 receive a good signal even where receiving unit 777 is not aligned with the center of PCMD 700. Where one LED at the center of a PCMD is used (as in FIG. 1) but the receiving unit in the electronics module is offset from the center, a poor signal or no signal may be received because the LED directs light in a limited cone. The receiving unit 777 may be offset because the E-coil occupies a space covering the center of the PCMD. Thus, it is desirable to have one of LEDs 728�731 aligned with the offset position of the receiving unit 777. This requires more than one LED (four, in this example) so that one LED is below the receiving unit regardless of the rotational orientation of the PCMD 700. However, for energy efficiency it is desirable to transmit via only one LED. Therefore, a technique is provided for determining the optimum LED to transmit data.
The optimum LED is determined as part of a hand-shaking routine between the electronics module 708 and the PCMD 700. First, the electronics module 708 sends a signal to the PCMD 700 via the RF coil 708, telling PCMD 700 to begin transmission. The PCMD 700 begins transmitting using LED 728. If the electronics module 708 does not receive a signal after a predetermined time, another signal is sent to the PCMD 700 requesting a transmission. The PCMD 700 transmits using LED 729. If receiving unit 777 receives no signal, then LED 730 is used. If no signal is received from LED 730, then 731 is used. Because LED 731 is directly below receiving unit 777, the signal is received and LED 731 is identified as the optimum LED The PCMD then uses only the optimum LED 731 and may turn off the other LEDs 728�730 to conserve energy. More LEDs may be used depending on the configuration of the receiving unit or units. LEDs maybe arrayed in different locations and pointed in different directions depending on where the data is to be sent.
Utilizing the limited storage capacity of the power sources efficiently is desirable to maximize the amount of data and measurement time of the PCMD. The sensor groups that are activated are user selectable, the groups are only activated when necessary. Outputs from selected groups are multiplexed and only written into memory at selected intervals. The output is also compressed to minimize the amount of time and energy needed to store the data.
As defined herein, �processing conditions� refer to various processing parameters used in manufacturing an integrated circuit. Processing conditions include any parameter used to control semiconductor manufacture or any condition a manufacturer would desire to monitor such as, but not limited to, temperature, processing chamber pressure, gas flow rate within the chamber, gaseous chemical composition within the chamber, position within a chamber, ion current density, ion current energy, light energy density, and vibration and acceleration of a wafer or other substrate within a chamber or during movement to or from a chamber. Different processes will inevitably be developed over the years, and the processing conditions will, therefore, vary over time. Therefore, whatever the conditions may be, it is foreseen that the embodiments described will be able to measure such conditions.
Sensors 124 are used for detecting various processing conditions are mounted on or fabricated in substrate 102 according to a well-known semiconductor transducer design. For measuring temperature, a popular transducer is an RTD or thermistor, which includes a thin-film resistor material having a temperature coefficient. A magneto-resistive material may also be used to measure the temperature through the amount of magnetic flux exerted upon substrate 102. A resistance-to-voltage converter is often formed within the substrate between distal ends of the resistive-sensitive material (either thermistor or magneto-resistive material) so that the voltage may easily be correlated with a temperature scale. Another exemplary temperature sensor includes a thermocouple made of two dissimilar conductors lithographically formed in the layers of the substrate. When the junction between the conductors is heated, a small thermoelectric voltage is produced which increases approximately linearly with junction temperature. Another example of a temperature sensor includes a diode that produces a voltage that increases with temperature. By connecting the diode between a positive supply and a load resistor, current-to-voltage conversion can be obtained from the load resistor. Another sensor is a piezoelectric device such as a quartz tuning fork fabricated from quartz crystal cut on a crystal orientation which exhibits a temperature dependent frequency of oscillation. The sensor's oscillating frequency can be referenced against a master oscillator formed by a piezoelectric device such as a quartz tuning fork, which is fabricated from a crystal oriented to minimize frequency change with temperature. The frequency difference between the sensor and master oscillator would provide a direct digital temperature dependent signal. Piezoelectric sensors may also be used to sense mass change to measure deposition mass and rates or other process conditions.
FIGS. 2A and 2B illustrate PCMD handling system (�HS�) 200. Handling system 200 generally speaking includes a user interface and various electronic components, including a microprocessor and memory, for transferring data to and from a number of PCMDs and for configuring, recharging, and transporting the PCMDs.
Substrates are typically stored and transported in a substrate carrier such as cassette 204. Processing tools are adapted to a particular standard substrate carrier. Typical tools have robots that move substrates from a substrate carrier through the tool and back to a substrate carrier. Substrate carriers within a facility are interchangeable so that the robot may be calibrated to a substrate carrier and continue to operate with similar substrate carriers without being recalibrated. A single substrate carrier standard is used so that a substrate carrier may be moved from one tool to another and the robot in each tool may transport substrates to and from the substrate carrier.
FIG. 8B shows a section of an edge of a PCMD 100 having greycode 850. Greycode provides a pattern that uniquely identifies locations at the edge of the wafer. Greycode is generally a code whereby successive words change by just one bit. On the wafer surface this is represented by changes between light and dark areas created by patterning a deposited layer. A word may be read along a radius such as A�A′ or B�B′. The word read at A�A′ would be 1,1,1,0, and at B�B′ would be 1,0,1,1, where light represents 1 and dark represents 0. This example uses a word of four bits. Using a word of 8 or 9 bits allows better resolution because a larger number of uniquely identified locations are possible. For example, with 8 bits, 256 different uniquely identified locations are possible. A reader, such as a linear array is used to determine the unique word at the location of the reader and also the position of the edge of the wafer. With two such readers, the rotational orientation of the wafer and the position of the center of the wafer may be found. The greycode may be located outside the area of the PCMD where the sensors are located so that sensors do not impinge on the greycode area and the greycode does not affect the sensors. Alternatively, where sensors impinge on the greycode area, the readers may be located so that at least one reader will be able to read the greycode. For example, where sensors are spaced 60 degrees apart near the edge of a PCMD, the readers may be spaced 90 degrees apart so that if one reader is aligned with a sensor then the other reader will have a clear reading. Both readers should still read the position of the edge of the PCMD so that the position of the center of the PCMD may be determined.
While rotation of a PCMD is not required to determine rotational orientation where a greycode is used, movement of a PCMD may be desirable for other reasons. Inductive coupling between PCMD 800 and electronics module 808 improves as the distance between them decreases. Improved alignment between the position of the center of PCMD 800 and electronics module 808 may also improve coupling. If the coupling is improved, energy transfer is more rapid and the time to recharge PCM 800 may be reduced accordingly. Communication may also be improved when PCMD 800 is correctly placed. Thus, moving PCMD 800 to the optimum position relative to electronics module 808 may be of value. Rotation of PCMD 800 may be desirable so that a particular rotational orientation of PCMD 800 may be selected. Typically, maintaining the same orientation from one survey to another will be desirable. In this way, data from one survey may be accurately compared with data from another survey as individual sensors collect data at the same locations each time. It may be necessary to rotate PCMD 800 for alignment with process chamber elements such as positioning of specific PCMD sensors over heating zones to correlate PCMD temperature profiles with heater zones. Sometimes, it is desirable to change the rotational orientation of a PCMD between surveys. A PCMD may have some inherent nonuniformity due to variation between individual sensors. Performing multiple surveys with different PCMD orientations allows the effects of such nonuniformity to be reduced or eliminated. For example, a PCMD may perform surveys at a first orientation, then at 90 degrees, 180 degrees and 270 degrees offset from the first orientation. The data from these surveys may then be averaged to provide a more accurate result.
Rotation stage 883 is a disk that protrudes above the tipper surface of housing 887. Rotation stage 883 may be rotated and may also be extended in the vertical direction. Rotation is possible in both the raised and lowered position but is typically performed in the raised position.
FIG. 8F�8H show alignment module 881 aligning PCMD 800. Each of FIGS. 8F�8H shows two perspectives. The left view is from above and to one side. The right view is a corresponding cross-sectional view. FIG. 8F shows PCMD 800 positioned above alignment module 881. PCMD 800 is held at its edges as in FIG. 8D. Arm 888 is retracted and is therefore not visible in this view. Rotation stage 883 is clear of PCMD 800. PCMD 800 may not be centered correctly at this point. This means that the center of PCMD 800 may not be directly under the center of an electronics module. Also, PCMD 800 may not have the desired rotational orientation. Either linear or rotational misalignment of PCMD 800 may be detected by greycode readers as described above. In order to obtain an accurate map of conditions measured by PCMD 800 the positions of the sensors on PCMD 800 must be known. Thus, any map generated assumes a certain rotational orientation. It is generally desirable that PCMD 800 be returned to this orientation if any change occurs.
FIG. 8H shows alignment module 881 with arm 888 in the retracted position (out of sight) and rotation stage 883 in a raised position. PCMD 800 is supported by rotation stage 883. PCMD 800 is clear of other parts of the handling system at this point. PCMD 800 may be rotated by rotation stage 883 until it reaches a desired orientation. PCMD 800 may remain in a raised position for recharging from electronics module 808. When recharging is complete, rotation stage 883 may be lowered and PCMD 800 may be returned to its normal position where it may be picked up by a robot blade that extends under it and lifts it from its slot.
In one embodiment, the transfer of data from handling system 980 is achieved by using an active RFID transmitter in handling system 980. This takes advantage of the presence of an RFID reader close to the FOUP to transmit data to a network where it may be accessed by an end-user. Semiconductor Fabrication facilities (Fabs) that use FOUPs generally track the individual FOUPs and their contents by means of RFID tags. Tags are generally passive devices capable of providing an identification number when they are interrogated by a reader. A reader is generally provided at the load port where a FOUP connects to a processing system so that the identity of the FOUP at the load port at any particular time is known. A network of such readers throughout the Fab are connected to a software system that can monitor the position of different FOUPS and coordinate the movement of FOUPs to optimize efficiency. Certain industry standards regarding such a network are detailed in �General model for communications and control of manufacturing equipment,� (GEM), SEMI E30 and SEMI E87-0703. The presence of such a reader connected to a network provides a convenient way to transfer data from a handling system to an end-user.
FIG. 2B shows the front or user side of HS 200. A memory card 228 is shown inserted into electronics module 208 and may be considered part of HS 200. HS 200 accommodates any number of memory card formats such as but not limited to the smartcard�, Sony memory stick�, the Secure Digital (�SD�) card�, Compact Flash (�CF�), or Multi-Media Card� (�MMC�). A PCMD is sent out �on a survey� to record the various conditions in different types of environments. For each environment and for the entire survey, it may be desirable to alter various parameters of the PCMD such as the sampling rate, sampling duration, and the sensors used. Display 232 quickly conveys information to a user regarding the setup of the PCMD such as the number and arrangement of sensors to be used in a survey, the length and times of the various cycles of a survey, and the sampling rate of the sensors and sensor electronics etc. A survey profile and the data retrieved on the survey may also be stored on the memory card 228 or within flash memory of electronics module 208.
FIG. 4B describes the process of making an embodiment with two conductive layers coupled by inter-level vias. Steps 404 and 408 are the same as those in FIG. 4A. In step 412, the first conductive layer 312A is formed on insulating layer 304. In step 413, a dielectric layer 310 is formed upon conductive layer 312A. After that, openings for vias 312C are formed in dielectric layer 310 in step 414. Next, in step 415, conductive layer 312B and vias 312C are formed on/in the dielectric layer 310. In step 416 electrical traces are patterned and etched in the exposed portion of conductive layers 312A and 312B. Steps 420�436 are the same as in FIG. 4A.
FIGS. 10A and 10B show examples of lids 1010�1013 protecting components 1020�1022 of the PCMD from the environment. In FIG. 10A a single lid is used for three components. The number of components covered by a single lid depends on the sizes and locations of the components but may be anything from one component to all the components in the PCMD. FIG. 10A shows three components 1020�1022 and the attached wire bonds 1048 covered by a single lid 1010. In FIG. 10B separate lids 1011�1013 are used for each component 1020�1022. Various materials may be used to form lids such as lids 1010�1013. For example, a ceramic lid similar to that used for packaging integrated circuits may be adapted to cover a component or group of components in a PCMD. For particularly harsh chemical environments lids may be made from materials such as sapphire that resist chemical attack. Where protection from electromagnetic fields is required, lids may be made of conductive material such as metal or doped silicon. For some applications, plastic lids may be used. Lids 1010�1013 are bonded to the substrate 1002 in a conventional manner.
In the example shown in FIG. 10D, a three layer structure is used. Traces (not shown) may be formed and components 1020�1022 may attached to substrate 1002 and bonded to the traces. Then, a second layer 1050 is put in place. This layer has cutouts formed for the components 1020�1022. This layer may be silicon so that it has similar characteristics to the substrate 1002. Next, a lid 1030 is attached to the upper surface of layer 1050. This method allows cavities to be uniform in depth because the depth of each cavity is equal to the thickness of layer 1050. Also, the upper and lower surfaces of layer 1050 may be highly planar providing good attachment to substrate 1002 and lid 1030.
When robot blade detector 886 detects a robot blade approaching PCMD 800, moving parts that might interfere with the robot blade must be placed in positions where they do not interfere. Where E-coil 810 is lowered to improve coupling with PCMD 800, it must be retracted before the robot blade attempts to lift PCMD 800. Typically, this means that it must be retracted within 0.1�0.3 seconds from the time that a robot blade is detected by robot blade detector 886.
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