Abstract:
In at least one aspect, a method includes positioning a load lock of an electronic device manufacturing tool such that the load lock occupies a first floor area; and positioning a mainframe power supply in a second floor area, wherein a substantial portion of the second floor area is within the first floor area, thereby reducing the electronic device manufacturing tool footprint. Additionally, or alternatively, a mainframe controller may be placed so that the footprint thereof substantially overlaps the footprint of the load lock. Numerous other aspects are also provided.

Description:
[0001]     The present application claims priority from U.S. Provisional Patent Application Ser. No. 60/587,110, Filed Jul. 12, 2004 (Attorney Docket No. 9081/L), which is hereby incorporated by reference herein in its entirety. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates generally to electronic device manufacturing, and more particularly to methods and apparatus for reducing an electronic device manufacturing tool footprint.  
       BACKGROUND  
       [0003]      FIG. 1  illustrates a conventional electronic device manufacturing tool (or system)  101 . With reference to  FIG. 1 , the electronic device manufacturing tool  101  includes components, such as a mainframe power supply (e.g., a mainframe power box)  103  and a mainframe controller  105 , coupled to a mainframe  107 . The mainframe  107  may include one or more processing chambers  109 , each of which is coupled to a respective processing chamber power box  110  and processing chamber controller  111 , and a transfer chamber  112  coupled to a load lock  113 . A footprint of the electronic device manufacturing tool  101  is the area of a floor (e.g., in a clean room)  115  occupied by the electronic device manufacturing tool  101 . The mainframe power box  103  and mainframe controller  105  are coupled to a rack  117  (e.g., an enclosure rack) separate from the mainframe  107 . Therefore, the mainframe power box  103  and controller  105  occupy a floor space  118  separate from the mainframe of the electronic device manufacturing tool  101 , thereby increasing the electronic device manufacturing tool&#39;s footprint.  
         [0004]     Further, the mainframe power box  103  and controller  105  are coupled to the mainframe  107  via wiring  119 , which extends from the separate rack  117  to the mainframe  107 . Therefore, the farther the separate rack  117  is located from the mainframe  107 , the more wiring  119  is required by the electronic device manufacturing tool  101 , which reduces system integration. As described below, reducing the electronic device manufacturing tool footprint may increase tool (or system) integration.  
         [0005]     Accordingly, methods and apparatus for reducing an electronic device manufacturing tool footprint are desired.  
       SUMMARY OF THE INVENTION  
       [0006]     In a first aspect of the invention, a first method is provided for reducing an electronic device manufacturing tool&#39;s footprint. The first method includes the steps of (1) positioning a load lock of an electronic device manufacturing tool such that the load lock occupies a first floor area; and (2) positioning a mainframe power supply in a second floor area, wherein a substantial portion of the second floor area is within the first floor area, thereby reducing the electronic device manufacturing tool footprint.  
         [0007]     In a second aspect of the invention, a second method is provided for reducing an electronic device manufacturing tool footprint. The second method includes the steps of (1) positioning a load lock of an electronic device manufacturing tool such that the load lock occupies a first floor area; and (2) positioning a mainframe controller in a second floor area, wherein a substantial portion of the second floor area is within the first floor area, thereby reducing the electronic device manufacturing tool footprint.  
         [0008]     In a third aspect of the invention, a third method is provided for reducing an electronic device manufacturing tool shipping cost. The third method includes the steps of (1) placing a load lock and a mainframe power supply of an electronic device manufacturing tool into a container; and (2) shipping the container.  
         [0009]     In a fourth aspect of the invention, a fourth method is provided for reducing an electronic device manufacturing tool shipping cost. The fourth method includes the steps of (1) placing a load lock and a mainframe controller of an electronic device manufacturing tool into a container; and (2) shipping the container.  
         [0010]     In a fifth aspect of the invention, a first apparatus is provided for reducing an electronic device manufacturing tool footprint. The first apparatus includes (1) a load lock frame; (2) a load lock of an electronic device manufacturing tool coupled to the load lock frame such that the load lock occupies a first floor area; and (3) a mainframe power supply coupled to the load lock frame such that the mainframe power supply occupies a second floor area. A substantial portion of the second floor area is within the first floor area, thereby reducing the electronic device manufacturing tool footprint.  
         [0011]     In a sixth aspect of the invention, a second apparatus is provided for reducing an electronic device manufacturing tool footprint. The second apparatus includes (1) a load lock frame; (2) a load lock of an electronic device manufacturing tool coupled to the load lock frame such that the load lock occupies a first floor area; and (3) a mainframe controller coupled to the load lock frame such that the mainframe controller occupies a second floor area. A substantial portion of the second floor area is within the first floor area, thereby reducing the electronic device manufacturing tool footprint.  
         [0012]     In a seventh aspect of the invention, a third apparatus is provided that includes (1) an electronic device manufacturing tool having a mainframe that occupies a first footprint, and (2) a mainframe power supply that occupies a second footprint that substantially overlaps the first footprint.  
         [0013]     In an eighth aspect of the invention, a fourth apparatus is provided that includes (1) an electronic device manufacturing tool having a mainframe that occupies a first footprint, and (2) a mainframe controller that occupies a second footprint that substantially overlaps the first footprint. Numerous other aspects are provided, as are systems and apparatus in accordance with these and other aspects of the invention.  
         [0014]     Other features and aspects of the present invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0015]      FIG. 1  illustrates a conventional electronic device manufacturing tool.  
         [0016]      FIG. 2  illustrates an exemplary electronic device manufacturing tool in accordance with an embodiment of the present invention.  
     
    
     DETAILED DESCRIPTION  
       [0017]     The present invention relates to increasing the integration and reducing the footprint of an electronic device manufacturing tool (or system).  FIG. 2  illustrates an exemplary electronic device manufacturing tool (or system)  201  in accordance with an embodiment of the present invention. The electronic device manufacturing tool  201  may be employed to manufacture and/or process substrates such as glass or polymer substrates used to manufacture flat panel displays, semiconductor wafers, etc. With reference to  FIG. 2 , the configuration of the exemplary electronic device manufacturing tool  201  is similar to the configuration of the conventional electronic device manufacturing tool  101  of  FIG. 1 . More specifically, the exemplary electronic device manufacturing tool  201  includes a mainframe  203 . The mainframe  203  includes one or more processing chambers  205 , each of which is coupled to a respective processing chamber power box  206  and processing chamber controller  207 , a transfer chamber  208  and a load lock  209 . The load lock  209  is supported by a load lock rack  211 .  
         [0018]     A mainframe power box (e.g., power supply)  213  of the exemplary electronic device manufacturing tool  201 , which provides power to the mainframe  203  and to each processing chamber power box  206 , is positioned differently than is the mainframe power box  103  of the conventional electronic device manufacturing tool  101 . More specifically, the load lock  209  is positioned (e.g., on the load lock rack  211 ) such that the load lock  209  occupies a first floor area  215 , and the mainframe power box  213  is positioned to occupy a second floor area  217 , a substantial portion of which is included in the first floor area  215 . For example, the first floor area  215  may include the entire second floor area  217 . The mainframe power box  213  is adapted to couple to the load lock rack  211 . For example, the mainframe power box  213  may couple to and be supported by the load lock rack  211  and/or be an integral part of the load lock  209 . For example, the mainframe power box  213  may be positioned below the load lock  209 . However, the mainframe power box  213  may assume other positions, such as above the load lock  209 . Therefore, according to the configuration of the exemplary electronic device manufacturing tool  201 , the load lock  209  and the mainframe power box  213  occupy at least substantially overlapping floor areas. In this manner, the footprint of the electronic device manufacturing tool  201  is reduced. Reducing the electronic device manufacturing tool footprint may reduce a required clean room size, which may lower the cost of operating the tool.  
         [0019]     Alternatively or additionally, in a similar manner to that described above, a mainframe controller  218  of the exemplary electronic device manufacturing tool  201  may be positioned differently than is the mainframe controller  105  of the conventional electronic device manufacturing tool  101 . For example, in embodiments in which both the mainframe power box  213  and the mainframe controller  218  are positioned so as to reduce the footprint of the manufacturing tool  101 , the mainframe controller  218  is positioned to occupy a floor area (e.g., a third floor area)  219 , a substantial portion of which is included within the first floor area  215 . For example, the first floor area  215  may include at least 50 percent of, or preferably the entire third floor area  219 . The mainframe controller  218  may be adapted to couple to and be supported by the load lock rack  211 . For example, the mainframe controller  218  may couple to a side of the load lock rack  211  opposite the side of the load lock rack  211  to which the mainframe power box  213  is coupled. Alternatively, the mainframe controller  218  may be coupled to other portions or sides of the load lock rack  211 . Further, the mainframe controller  218  may be positioned above or below the load lock  209 . Therefore, according to the exemplary configuration shown in  FIG. 2 , the load lock  209  and the mainframe controller  218  occupy overlapping floor areas. In this manner, the footprint of the electronic device manufacturing tool  201  is reduced.  
         [0020]     The position of the mainframe power box  213  and/or the mainframe controller  218  of the inventive electronic device manufacturing tool  201  may allow wiring  220  between the mainframe power box  213  and/or the mainframe controller  218  and other components of the electronic device manufacturing tool  201  to be reduced. More specifically, because of the position of the mainframe power box  213  and/or the mainframe controller  218 , the electronic device manufacturing tool  201  does not require wiring to be run from a separate enclosure to the mainframe  203  in order to couple the mainframe power box  213  and/or the mainframe controller  218  to the mainframe  203 . The wiring  220  between the mainframe power box  213  and/or the mainframe controller  218  and the mainframe  203  may fit compactly within the mainframe footprint. Therefore, in addition to reducing the footprint of the electronic device manufacturing tool, the present methods and apparatus may increase system integration and reduce system complexity.  
         [0021]     In accordance with an embodiment of the present invention the exemplary electronic device manufacturing tool  201  may be transported (e.g., shipped) more efficiently than the conventional electronic device manufacturing tool  101 . More specifically, conventionally, the mainframe power box  103  and mainframe controller  105  are shipped separately from the load lock  113  of the conventional electronic device manufacturing tool  101 . In contrast, the mainframe power box  213  of the inventive electronic device manufacturing tool  201  may be shipped with the load lock  209 . As described above, the mainframe power box  213  may be adapted to couple to the load lock rack  211  and occupy an overlapping footprint with the load lock  209 . Therefore, the load lock  209  and the mainframe power box  213  of the inventive electronic device manufacturing tool  201  (e.g., which may both be assembled to the load lock rack  209 ) may be shipped in the same container. By shipping the load lock  209  and the mainframe power box  213  in the same container, a total number of containers required to ship the exemplary electronic device manufacturing tool  201  is reduced. Consequently, the electronic device manufacturing tool shipping cost is reduced. Alternatively or additionally, in a similar manner, the mainframe controller  218  may be shipped in the same container as the load lock  209 .  
         [0022]     The foregoing description discloses only exemplary embodiments of the invention. Modifications of the above disclosed apparatus and methods which fall within the scope of the invention will be readily apparent to those of ordinary skill in the art. In one or more embodiments, a substantial portion (e.g., at least 50 percent, and preferably 100 percent) of the floor area occupied by the mainframe power box  213  and/or the mainframe controller  218  (e.g., a second and/or third floor area, respectively) is within the floor area occupied by the load lock  209  (e.g., a first floor area  215 ). However, in other embodiments, a substantial portion of the floor area occupied by the mainframe power box  213  and/or the mainframe controller  218  may be within the floor area occupied by another component of the electronic device manufacturing tool  201 . For example, the mainframe power box  213  and/or the mainframe controller  218  may be coupled to another component of the electronic device manufacturing tool  201  or to a support rack of that component.  
         [0023]     Accordingly, while the present invention has been disclosed in connection with exemplary embodiments thereof, it should be understood that other embodiments may fall within the spirit and scope of the invention, as defined by the following claims.