Abstract:
A containment device for retaining semiconductor wafers having a first housing member having a frame with inner and outer walls normal to the frame having a gapped relation. The inner wall receives the semiconductor wafers. A second housing member securably attachable to the first housing member by plural latches has a frame forming the top of the device. Each latch has a hook secured to the first housing member passing through a hole in the second housing member and releasably secured within the hole by the hook. In a second embodiment, the latches and holes are replaced with a plurality of rotatable latch members each having a hook at the distal end for engagement with a hole in the second housing member, secured to the first housing member and rotatable about a hinge. One wall of the first embodiment is replaced with a soft liner which absorbs shock.

Description:
CROSS REFERENCE TO PRIOR APPLICATIONS 
     This application is a division of Ser. No. 09/571,654, filed May 15, 2000, which is a continuation-in-part of Ser. No. 09/298,103, filed Apr. 22, 1999 now U.S. Pat. No. 6,193,068 which claims priority based upon Provisional Application Serial No. 60/084,612, filed May 7, 1998, the contents of both of which are incorporated herein by reference. 
    
    
     TECHNICAL FIELD OF THE INVENTION 
     This invention relates in general to a containment device and in particular to a containment device for retaining semiconductor wafers that provide for automated loading and unloading of the semiconductor wafers therein while minimizing the breakage of the semiconductor wafers during loading, unloading and transporting. 
     BACKGROUND OF THE INVENTION 
     Without limiting the scope of the present invention, its background will be described with reference to transporting semiconductor wafers from one site to another. 
     Heretofore in this field, it has been necessary to transport semiconductor wafers from one fabricating facility to another between certain steps in the fabrication process. The process for packaging the semiconductor wafers for transport was typically a manual process which required placing each of the semiconductor wafers into individual electrostatic discharge bags in order to prevent the buildup of static charge on the semiconductor wafer that may otherwise occur during handling. The static charge must be prevented in order to avoid causing short circuits within the semiconductor wafer. 
     Once the semiconductor wafers were placed into electrostatic discharge bags, the semiconductor wafers were placed into a styrofoam box. The styrofoam box was typically treated with a topical anti-static coating such as Staticide made by ACL Corporation or other quaternary compounds. The use of the topical anti-static coating on the styrofoam box further prevented the buildup of static charge during handling of the semiconductor wafers. 
     It has been found, however, that the use of styrofoam boxes can promote the corrosion of semiconductor wafers due to the potential moisture retention by the styrofoam. The typical process used to mold the styrofoam box is a steam process wherein beads of styrofoam are exposed to steam which causes them to expand and allows them to be formed into the shape of a box. If the styrofoam boxes are not properly dried, the residual moisture within the styrofoam box may cause corrosion of the semiconductor wafers. 
     The use of styrofoam boxes also left semiconductor wafers susceptible to breakage. For example, it is estimated that between one and three percent of semiconductor wafers were broken during the manual loading and unloading process as well as during transportation of the semiconductor wafers in the styrofoam box. In addition, the use of styrofoam boxes to transport silicon wafers resulted in high costs associated with the manufacture and disposal of the styrofoam boxes which, in most cases, were not re-used or recycled. 
     Therefore, a need has arisen for a containment device for retaining semiconductor wafers that will allow for automated loading and unloading of semiconductor wafers, thereby minimizing the breakage of semiconductor wafers associated with the transportation of semiconductor wafers from one facility to another. A need has also arisen for such a containment device that dissipates static charge without the need to manually place the semiconductor wafers within an electrostatic discharge bag. A need has further arisen for a containment device for retaining semiconductor wafers that does not promote corrosion of the semiconductor wafers. Additionally, a need has arisen for such a containment device that is re-usable, thereby minimizing both the manufacturing and disposal costs associated with transporting semiconductor wafers. 
     SUMMARY OF THE INVENTION 
     The present invention disclosed herein comprises a containment device for retaining semiconductor wafers that provides for automated loading and unloading of the semiconductor wafers therein while minimizing the breakage of the semiconductor wafers during loading, unloading and transporting. The containment device of the present invention dissipates static electricity through the use of electrically conductive materials and does not promote corrosion of the semiconductor wafers as the materials used do not retain moisture. Additionally, the containment device of the present invention is reusable, thereby reducing both the manufacturing and environmental costs associated with transporting semiconductor wafers. 
     The containment device in accordance with a first embodiment of the present invention comprises a first housing member having a frame, an inner wall and an outer wall. The inner and outer walls extend generally perpendicularly from the frame and have a spaced apart relationship forming a gap therebetween, the inner wall closely spaced from the semiconductor wafers when receiving the semiconductor wafers to prevent radial movement of the semiconductor wafer during transportation. The containment device also includes a second housing member that is securably attachable to the first housing member. The second housing member has a frame that forms the top of the containment device when the first and second housing members are securably attached together. 
     The inner and outer walls of the containment device each have a slot that allows for automated loading and unloading of semiconductor wafers. In addition, the inner wall has a notch for establishing the maximum depth of semiconductor wafers to be retained within the containment device. Both the frame of the first housing member and the frame of the second housing member may include reinforcement members for minimizing flexure of the containment device during transportation. The second housing member may further include a wall that extends generally perpendicularly from the frame of the second housing member that is disposed exteriorly of the outer wall of the first housing member when the first and second housing members are securably attached together. The frame of the second housing member may also include a spacer member that minimizes the axial movement of the semiconductor wafers within the containment device when the first and second housing members are securably attached together. 
     The first housing member and the second housing member are securably attached together using one or more latches that are hingably mounted to the first housing member. In first embodiments, each latch is attached to the first housing member and has a hook that is received and secured within a hole in the frame of the second housing member. The latches and holes receiving the latches are preferably positioned 180 degrees apart when two such latches are used and 90 degrees apart when four such latches are used, ot being understood that the number of latches used can be any number greater than one. The use of, for example, four spaced apart latches as compared to two spaced apart latches provides for greater flattnes of the housing as the housing diameters increase, such as, for example up to 300 mm. The latches are disposed at corners or sides of the housing with the corners being preferred, especially when the housing is the preferred rectangular (square) shape, it being understood that the housing can have other shapes, such as, for example circular. Once the first housing member and the second housing member are securably attached together, similar containment devices may be stacked one on top of another using the respective lips of the first housing members and the second housing members. In accordance with a second embodiment, a rotatable flap is secured to the first housing member and has a hook on the distal end thereof for overlapping the second housing member and entering an aperture on the top of the second housing member to provide the latching action. A plurality of such rotatable flaps are used, the embodiment shown having two such flaps, it being understood that additional such flaps can also be provided in spaced relation in the same manner as discussed above with reference to the first embodiments. 
     Prior to loading the containment device with semiconductor wafers in accordance with the first embodiments, a cushion is placed in the bottom of the first housing member. A wafer separator is then place on top of the cushion. Thereafter, numerous semiconductor wafers are place within the containment device and closely received within the inner wall of the first housing member using an automated process. This process includes placing a wafer separator between each semiconductor wafer. Once the level of the semiconductor wafers reaches the notch of the inner wall of the first housing member, a cushion is placed on top of the last semiconductor wafer with a wafer separator therebetween. The second housing member may then be securely attached to the first housing member. 
     The materials selected for the containment device of the present invention must not only protect the semiconductor wafers from impacts or shocks to the exterior of the containment device but must also protect the semiconductor wafers from the ubiquitous build up of internal static. Specifically, the first and second housing members are constructed from a conductive material such as a carbon impregnated polypropylene. Similarly, the wafer separators are constructed from a conductive material which may be a carbon impregnated polyethylene. Additionally, the cushions used above and below the stack of semiconductor wafers may be constructed from an anti-static foam. 
     In accordance with the second embodiment of the invention, the outer wall is not provided and, instead, the remaining wall, which corresponds to the inner wall of the first embodiments, is lined with a very soft rubber or foam or the like, preferably of an antistatic variety, such as pink polyethylene antistatic foam, which will absorb shock applied to the housing. This embodiment provides added shock protection and becomes more useful as the diameters of the wafers increase and/or as the thicknesses of the wafers decrease. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a more complete understanding of the present invention, including its features and advantages, reference is now made to the detailed description of the invention, taken in conjunction with the accompanying drawings in which like numerals identify like parts and in which: 
     FIG. 1 is a top view of the lower portion of a containment device of the present invention; 
     FIG. 2 is a side view of the containment device of FIG. 1; 
     FIG. 3 is a cross sectional view of the containment device of the present invention taken along line  3 — 3  of FIG. 1; 
     FIG. 4 is a bottom view of the lower portion of a containment device of the present invention; 
     FIG. 5 is a top view of the upper portion of a containment device of the present invention; 
     FIG. 6 is a cross sectional view taken along line  6 — 6  of FIG. 5; 
     FIG. 7 is a bottom view of the upper portion of a containment device of the present invention; 
     FIG. 8 is a side view of the upper portion of the containment device of FIG. 7; 
     FIG. 9 is a side view of the upper portion of the containment device of FIG. 7; 
     FIG. 10 is a cross sectional view of the lower portion of a containment device of the present invention having semiconductor wafers loaded therein. 
     FIG. 11 is a top view of the lower portion of a containment device in accordance with a second form of the first embodiment of the present invention; 
     FIG. 12 is a top view of the upper portion of a containment device in accordance with a second form of the first embodiment of the present invention; 
     FIG. 13 is a top view of the bottom portion of a containment device in accordance with a second embodiment of the present invention; 
     FIG. 14 is a side view of the bottom portion of FIG. 13; 
     FIG. 15 is a top view of the upper housing portion in accordance with the second embodiment of the invention; 
     FIG. 16 is a bottom view of the upper housing portion in accordance with the second embodiment of the invention; and 
     FIG. 17 is a cross sectional view of the second embodiment of the invention shown in assembled state. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While the making and using of various embodiments of the present invention is discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention. 
     Referring to FIG. 1, a lower housing member of a containment device for retaining semiconductor wafers is depicted and generally designated  10 . Lower housing member  10  includes a substantially planar frame  12  upon which semiconductor wafers will be placed. Extending generally perpendicularly from frame  12  is inner wall  14 . Inner wall  14  is sized to closely receive the semiconductor wafers that will be retained within the containment device of the present invention. For example, inner wall  14  may be sized to receive 6 inch, 8 inch, 12 inch or other diameter semiconductor wafers. Also extending generally perpendicularly from frame  12  is an outer wall  16 . Between inner wall  14  and outer wall  16  is a gap  18 . Together outer wall  16  and gap  18  protect the semiconductor wafers from the direct transmission of forces that my contact outer wall  16  during the transportation of semiconductor wafers within the containment device of the present invention. 
     As best seen in FIG. 2, a pair of latches  20  extend generally perpendicularly from frame  12 . Each of the latches  20  includes a hook  22  that will securably attach lower housing member  10  to an upper housing member as will be more fully discussed with reference to FIG.  5 . 
     Referring now to FIGS. 1 and 3, outer wall  16  includes a pair of oppositely disposed slots  24 . Similarly, inner wall  14  has a pair of oppositely disposed slots  26 . Together, slots  24  and slots  26  allow for the automated loading and unloading of semiconductor wafers using a typical wafer loading arm. In addition, inner wall  14  includes a pair of oppositely disposed notches  28  that are used to determine the maximum height for stacking semiconductor wafers within lower housing member  10  of the containment device of the present invention. 
     Referring now to FIG. 4, a top view of lower housing member  10  is depicted. Frame  12  of lower housing member  10  includes a plurality of reinforcement members including ribs  30  and rings  32 . As best seen in FIG. 3, rings  32 , as well as ribs  30 , extend outwardly from the bottom surface of frame  12  and prevent the flexure of frame  12  during, for example, loading, unloading and transporting semiconductor wafers within the containment device of the present invention. Additionally, frame  12  includes an outer lip  34  that will mesh with an outer lip of an upper housing member of the containment device of the present invention as will be more fully explained with reference to FIG.  5 . 
     Lower housing member  10  may be constructed from any suitably rigid material that provides support and containment for the semiconductor wafers to be disposed therein. For example, lower housing member  12  may be constructed from a plastic such as polypropylene. In addition, it has been found that the use of a conductive material will minimize the buildup of static charge on the semiconductor wafers disposed within lower housing member  10 . For example, a carbon impregnated polypropylene is suitable for discharging such static buildup. 
     Referring now to FIG. 5, a top view of the upper housing member is depicted and generally designated  36 . Upper housing member  36  includes a frame  38  that is generally planar. Frame  38  includes a pair of oppositely disposed holes that are designed to receive hooks  22  of latches  20  of lower housing member  10 . In operation, latches  20  are hingably attached to lower housing member  10  such that hooks  22  may be radially deflected outward as the inner surface of holes  40  come in contact with the angled surface of hooks  22  as best seen in FIG.  2 . When hooks  22  extend above holes  40 , latches  20  snap radially inwardly so that hooks  22  overlap the inner edge of holes  40  such that lower housing member  10  and upper housing member  36  are securably attached together. 
     Frame  38  of upper housing member  36  includes an outer lip  42 . Outer lip  42  is sized such that it may be closely received within outer lip  34  of lower housing member  10  as best seen in FIG.  3 . As such, similarly designed containment devices may be stacked together in a secure manner thereby preventing potential damage to the semiconductor wafers stored therein as the containment devices of the present invention are transported from one location to another. 
     As best seen in FIG. 6, frame  38  includes a series of reinforcement members in the form of concentric rings such as ring  44 . The reinforcement members minimize the flexure of upper housing member  36  such that when upper housing member  36  and lower housing member  10  are securably attached together, protection is provided for the semiconductor wafers disposed therein. Inwardly extending from frame  38  is a spacer  46  that contacts the upper surface of the semiconductor wafers stacked within the containment device of the present invention. Spacer  46  minimizes the axial movement of the semiconductor wafers within the containment device of the present invention during the transportation of the semiconductor wafers. 
     Referring now to FIG. 7, a bottom view of upper housing member  36  is depicted. Upper housing member  36  has a wall  48  that extends generally perpendicularly to frame  38 . Wall  48  is sized such that when upper housing member  36  is securably attached to lower housing member  10 , wall  48  is exteriorly disposed about outer wall  16  of lower housing member  10 . Upper housing member  36  also has a pair of oppositely disposed walls  50  that have a planar surface, as best seen in FIGS. 7 and 8. Walls  50  allow adjacent containment devices of the present invention to be packed tightly together in, for example, a shipping box or pallet. Additionally, upper housing member  36  has a pair of oppositely disposed planar walls  52  that provide for tight packing of adjacent containment devices as best seen in FIG.  9 . 
     Referring now to FIG. 10, a cross sectional view of lower housing member  10  loaded with a plurality of semiconductor wafers  54  is depicted. Prior to loading lower housing member  10  with semiconductor wafers  54 , a cushion  56  is placed on the upper surface of frame  12 . Cushion  56  provides protection to semiconductor wafers  54  from external shock. Cushion  56  may be constructed from an anti-static foam such that static charge will not develop between cushion  56  and a semiconductor wafer  54 . On top of cushion  56  is a wafer separator  58 . Wafer separator  58  is constructed from a conductive material having low ionic contamination and minimal loose particles. For example, wafer separator  58  may be constructed from a carbon impregnated polyethylene. The ionic contamination of wafer separator  58  should not exceed 20 ng/cm 2  of fluoride ions, chloride ions or sodium ions, should not exceed 30 ng/cm 2  of potassium ions or ammonium ions and should not exceed 40 ng/cm 2  of bromide ions, phosphate ions, nitride ions or sulfate ions. Additionally, wafer separator  58  should not have more than 100,000 loose particles per cubic foot that exceed 0.5 micrometers. 
     On top of wafer separator  58  is a semiconductor wafer  54 . Thereafter, a plurality of wafer separators  58  and semiconductor wafers  54  may be stacked in sequence. On top of the last semiconductor wafer  54  there is a wafer separator  58 . On top of the last wafer separator  58  is an additional cushion  56  that also protects semiconductor wafers  54  from impacts. 
     Referring now to FIGS. 11 and 12 there is shown a second form in accordance with the first embodiment of the invention wherein all elements are identical to the first embodiment except that four latches  20 , each with a hook  22 , are provided, one latch at each corner of the lower housing and the upper housing includes four holes  40  for receiving the latches  20  and hooks  22 . The operation is otherwise the same as in the first form of the first embodiment. 
     Referring to FIGS. 13 to  17 , there is shown a second embodiment in accordance with the present invention. In accordance with the second embodiment of the invention, the outer wall is not provided and, instead, the remaining wall  60 , which corresponds to the inner wall of the first embodiments, is lined with a very soft rubber or foam or the like  62 , preferably of an antistatic variety, such as pink polyethylene antistatic foam, which will absorb shock applied to the housing as shown in FIGS. 15 and 16. This embodiment provides added shock protection and becomes more useful as the diameters of the wafers increase and/or as the thicknesses of the wafers decrease. In accordance with this embodiment, the latches  20  with hooks  22  thereon and the holes  40  for receiving the latches are replaced, the latches being replaced by flaps  64  with hooks  66  at the distal end of each flap and the holes  40  are replaced with a recess  68  in the upper housing for receiving the hooks. The latches  64  are secured to the lower housing, preferably at the bottom of the lower housing as shown and are rotatable about a thinned or scored region  70  so that the latch can be rotated with the hook  66  travelling over the upper housing portion and into the recess  68  in the upper housing portion to provide the locking action and retain the upper and lower housing portions together. The latches  64  are preferably molded along with the lower housing as a single unit with the thin region or score region  70  provided as a part of the molding operation. The upper and lower housings are preferably polypropylene. The upper housing portion contains a downwardly depending member  72  at its inner surface which will impinge against the protective material disposed between the member  72  and the uppermost wafer to provide a minimal force which prevents the wafers from movement within the housing. The housing in accordance with the second embodiment is loaded in the same manner as described above with reference to the first embodiment and the materials for the housing portions are the same as described above with reference to the first embodiment. The upper and lower housing members are shown in assembled state in FIG. 17 with like character references depicting the same structures as in the first embodiments. 
     While this invention has been described with a reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.