Abstract:
The equipment comprises a semiconductor-processing device in which a load-lock chamber, a transfer chamber and a reaction chamber are modularized into, a main frame, a stand-alone chamber frame on which the semiconductor-processing device is placed, a sliding mechanism for enabling attaching/removing of the chamber frame to/from the main frame smoothly, and a positioning mechanism for fixing a position of the chamber frame. This enables the processing device to be attached and removed at will. The method comprises pulling out from the main frame the chamber frame, on which the modularized semiconductor-processing device is placed; forming a maintenance space inside the main frame; maintaining the semiconductor-processing device and peripherals attached in the vicinity of the main frame, and putting the chamber frame with the processing device back into the main frame.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to a device for installing a modularized semiconductor-processing device on a main frame and a method for maintaining the modularized semiconductor-processing device and peripherals. 
   2. Description of the Related Art 
   In Japanese Patent Application No. 2001-196802, which is incorporated herein by reference, there is disclosed modularized semiconductor manufacturing equipment including a load-lock chamber, a transferring mechanism and a reaction chamber.  FIG. 1  shows compact single-wafer-processing type semiconductor manufacturing equipment for forming a thin film on a semiconductor substrate, which is disclosed in the above-mentioned reference. FIG.  1 ( a ) is a plan view, FIG.  1 ( b ) is a front view, and FIG.  1 ( c ) is a side view of the equipment respectively. This equipment comprises a modularized reactor unit, an AFE portion [the portion which includes an atmosphere robot  5  for carrying in/out a substrate from within a cassette or a front opening unified pad (FOUP)  6  into/from a load-lock chamber] and a load boat in which the cassette or the FOUP  6  is positioned. The reactor unit is modularized by connecting two adjacent units. Each of the units comprises a reactor  1  for growing a film on a semiconductor substrate, a load-lock chamber  3  used for keeping the semiconductor substrate ready in vacuum, which is directly connected with the reactor  1  via a gate valve  2 , and a wafer handler  4 , which is positioned inside the load-lock chamber  3 . The wafer handler has one thin link-type arm for transferring a semiconductor substrate into the reactor  1  and moves the substrate in a straight-line direction. Modularizing the reactor units minimizes dead space inside the reactor unit and reduction in a faceprint  7  of the entire equipment. 
   FIGS.  2 ( a ) to ( d ) illustrate the operation sequences of the semiconductor manufacturing equipment disclosed in the above-mentioned reference. In FIG.  2 ( a ), the atmosphere robot  5  carries a semiconductor substrate  20  from a cassette or a FOUP into respective load-lock chambers  3  via a flapper valve  21 . After this is completed, the flapper valve  21  is closed and air in the load-lock chamber  3  is evacuated. In FIG.  2 ( b ), the gate valve  2  is opened and the semiconductor substrate is transferred onto a susceptor  22  inside the reactor  1  by a wafer handler mechanism  4 . Because the wafer handler only reciprocates between the load-lock chamber and the reactor in a straight-line direction, only positioning is required, and no complicated teaching and adjustment are required. In FIG.  2 ( c ), wafer support pins  23  protrude from a susceptor surface and support the semiconductor substrate  20 . The arms of the wafer handler mechanism  4  are housed in the load-lock chamber and the gate valve is closed. In FIG.  2 ( d ), the susceptor  22  is raised and the semiconductor substrate  20  is placed on the surface of the susceptor  22 . Afterward, a thin film formation onto the semiconductor substrate  20  is started. After thin film formation is completed, the processed semiconductor substrate is transferred to a cassette or a FOUP in a reverse sequence of FIGS.  2 ( d )→( c )→( b )→( a ). In addition to a single-wafer-processing type, the modularized semiconductor-processing device is capable of handling multiple substrates simultaneously and of executing deposition processing simultaneously. Consequently, device throughput is high, and stable processes are provided. 
   Generally, conventional load-lock type semiconductor manufacturing equipment comprised a load-lock chamber, a transfer chamber and a reaction chamber, and each chamber was directly attached to the main frame. Because of the construction, the only way of performing equipment maintenance was from the outside. Consequently, providing a space for maintenance work outside the equipment was required. Additionally, there was dead space in which no one was able to get in the center portion of the main frame, causing a problem that equipment footprint was increased when two units or more of the equipment were arranged transversely. 
   When maintenance is performed, workers are compelled to do jobs within such narrow area and work becomes extremely difficult when a critical failure occurs. As a result, equipment downtime lengthens and throughput declines. 
   The present invention was achieved in view of the above-mentioned problems. The object of the present invention is to provide semiconductor manufacturing equipment for which maintenance work can be performed easily and a maintenance method for the same. 
   The second object of the present invention is to provide compact semiconductor manufacturing equipment for which there is no space for maintenance required and no dead space, hence the entire equipment footprint is small. 
   The third object of the present invention is to provide semiconductor manufacturing equipment which reduces the time required for manufacturing devices and maintenance and improves throughput and a maintenance method for the same. 
   SUMMARY OF THE INVENTION 
   To achieve the above-mentioned objects, the semiconductor manufacturing equipment according to the present invention comprises a semiconductor-processing device in which a load-lock chamber, a transfer chamber and a reaction chamber are modularized into a main frame, a stand-alone chamber frame on which the semiconductor-processing device is placed, a sliding mechanism for enabling attaching/removing of the chamber frame to/from the main frame smoothly, and a positioning mechanism for fixing a position of the chamber frame, and which is characterized in that the modularized semiconductor-processing device is installed on the main frame in a manner that it can be attached and removed at will. 
   Preferably, the sliding mechanism comprises a guide component attached to the sliding surface of the bottom of the main frame and bearings or resin plates, which are attached to the sliding surface of the bottom of the chamber frame. 
   Preferably, the positioning mechanism comprises a bearing for positioning a y-axis direction, which is provided on the contact surface of the bottom of the main frame and wedge-shaped blocks for positioning x-axis and the z-axis directions. 
   Multiple units of the semiconductor manufacturing equipment can be arranged transversely with no space between the units. 
   The method for maintaining the semiconductor manufacturing equipment comprises the steps of pulling out the chamber frame, on which the modularized semiconductor-processing device is placed, from the main frame; forming a maintenance space inside the main frame; maintaining the semiconductor-processing device and peripherals attached in the vicinity of the main frame; and putting the chamber frame, on which the modularized semiconductor-processing device is placed, back into the main frame. 

   
     BRIEF DESCRIPTION OF THE FIGURES 
       FIG. 1  shows conventional modularized semiconductor manufacturing equipment. 
       FIG. 2  shows an operation sequence of conventional modularized semiconductor manufacturing equipment. 
       FIG. 3  shows a preferred embodiment and a maintenance sequence of the semiconductor manufacturing equipment according to the present invention. 
       FIG. 4  shows another preferred embodiment and a maintenance sequence of the semiconductor manufacturing equipment according to the present invention. 
       FIG. 5  is a plan view of two units of the semiconductor manufacturing equipment according to the present invention arranged and a maintenance method for this arrangement. 
       FIG. 6  is a side view of two units of the semiconductor manufacturing equipment according to the present invention arranged and maintenance spaces for performing maintenance work. 
       FIG. 7  is a plan view of multiple units of the semiconductor manufacturing equipment according to the present invention arranged and a maintenance method for this arrangement. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring to  FIG. 3 , the preferred semiconductor manufacturing equipment  30  according to the present invention comprises a main frame  31 , a modularized semiconductor-processing device  32  and a chamber frame  33  on which the semiconductor-processing device  32  is placed. A pair of spaced guides or rails  34  are attached respectively to the opposing bottom main frame members along an x-axis direction of the main frame  31 . Bearings or resin plates reducing friction resistance are installed on sliding surfaces  35  of the chamber frame, which slide along the guides  34  of the main frame  31 , enabling smooth sliding of the surfaces  35  or guides  34 . With this sliding mechanism, the modularized semiconductor-processing device  32  is installed in a manner that it can be attached and removed at will. 
   Wedge-shaped blocks  36  are attached to bottom main frame members along a y-axis direction, in which the chamber frame  33  contacts inside the main frame  31 . Positioning of the x-axis direction and the y-axis direction of the chamber frame  33  is determined by the block  36  fitting in a concave portion  302  provided in the chamber frame  33 . A bearing  37  is attached to the center of the wedge-shaped block  36  of the main frame. Positioning of a y-axis direction of the chamber frame  33  is determined by the bearing  37  fitting in a concave portion  301  provided in the chamber frame  33 . Two spaced pressing blocks  38  are attached to bottom main frame members along the y-axis direction adjacent the ends of the guides  34 . The pressing blocks  38  function so that the bottom frame along a y-axis direction of the chamber frame  33  is pressed against the main frame  31  after the chamber frame  33  is completely installed inside the main frame  31 . By this function, positioning of an x-axis direction and a y-axis direction of the chamber frame  33  inside the main frame  31  is determined. With the positioning mechanism, re-teaching of an AFE robot for enabling the chamber frame once pulled out to be fixed at the identical position can be eliminated. 
   FIGS.  3 ( a ) and ( e ) show that, when the modularized semiconductor-processing device  32  is installed, it is loaded inside the main frame  31  with no space between them. 
   Thus, the modularized semiconductor-processing device  32  is integrated with the chamber frame  33 , and it can be moved freely and separately from the main frame  31  by attaching casters  39  at its bottom. This feature facilitates a worker to perform adjustment work of a reactor and a load-lock chamber by pulling out the modularized semiconductor-processing device from the main frame  31 . At the time of a serious failure, an entire assembly can be replaced by replacing a module. 
     FIG. 4  shows another embodiment of the semiconductor manufacturing equipment according to the present invention. The semiconductor manufacturing equipment  40  comprises a main frame  41 , a modularized semiconductor-processing device  32  and a chamber frame  43  on which the semiconductor-processing device  32  is placed. A V-shaped groove  47  is provided along an x-axis direction on the bottom of the main frame  41 . A flat groove  48  is provided on the bottom of the main frame  41  opposing the V-shaped groove  47  along an x-axis direction. The V-shaped groove  47  and the flat groove  48  function as a positioning mechanism in the y-axis direction of the chamber frame  43  as well. Bearings or resin plates are attached to the V-shaped groove  47  and the flat groove  48  for reducing friction resistance, enabling smooth sliding of the V-shaped groove  47  and the flat groove  48  along the sliding surfaces  408  of the chamber plate. With this sliding mechanism, the modularized semiconductor-processing device  32  is installed on the main frame  41  in a manner that it can be attached and removed at will. Shock absorbers  44  are attached to side surfaces of the V-shaped groove  47  and the flat groove  48  of the main frame  41  so that the main frame  41  does not experience a shock caused by inertia when the chamber frame  43  is installed. 
   Casters  42  are attached at the rear end of the bottom of the chamber frame  43 . The casters  42  provide a support when the chamber frame  43  is pulled out and function as a positioning plate in the x-axis direction when the chamber frame  43  is installed. A leveling adjuster  49  is attached so that leveling in a z-axis direction can be done by the chamber frame alone when a chamber is assembled, etc. One sliding surface  46  of the chamber frame  43  protrudes in a V-shape to accommodate the V-shaped groove  47  of the main frame  41 . With the sliding surface  46  protruding in the V-shape sliding with the V-shaped groove  47 , positioning of a y-axis direction of the chamber frame  43  is determined. With the positioning mechanism, re-teaching of an AFE robot for enabling the chamber frame once pulled out to be fixed at the identical position can be eliminated. 
   FIG.  4 ( a ) demonstrates that the modularized semiconductor-processing device  32  is loaded with no space between inside the main frame  41  at the time of installation. 
   The modularized semiconductor-processing device  32  is integrated with the chamber frame  43 . By attaching casters  42  at its bottom, the device can be moved freely and separately from the main frame  41  (FIG.  4 ( c )). This feature facilitates the worker to perform adjustment work of a reactor and a load-lock chamber by pulling out the modularized semiconductor-processing device from the main frame  41 . At the time of a serious failure, an entire assembly can be replaced by replacing a module. 
   Returning to  FIG. 3 , a maintenance method of the semiconductor manufacturing equipment according to the present invention is described. First, preparatory for pulling out the chamber frame  33  from the main frame  31 , the pressing blocks  38  are released (FIG.  3 ( a )). While the chamber frame  33  is pulled out gradually, casters  39  are attached to the rear end of the bottom of the chamber frame (FIG.  3 ( b )). By pulling out the chamber frame  33  further, casters  39  are attached to the front end of its bottom (FIG.  3 ( c )). With the chamber frame pulled out completely, maintenance of the load-lock chamber, the reactor and peripherals of the main frame is performed (FIG.  3 ( d )). Lastly, the chamber frame is installed by positioning it inside the main frame  31 , and is fixed with the pressing blocks (FIG.  3 ( e )). 
   FIG.  5  and  FIG. 6  illustrate a maintenance method when two units of the semiconductor manufacturing equipment according to the present invention are arranged transversely.  FIG. 5  shows a plan view of the entire semiconductor manufacturing equipment.  FIG. 6  shows its side view. The entire semiconductor manufacturing equipment comprises a load boat portion in which cassettes or FOUP&#39;s  50  are positioned, an AFE portion including atmosphere robots  51 , and a modularized reactor unit portion  52 . FIG.  5  and  FIG. 6  show a position in which one of the reactor units  53  of the semiconductor manufacturing equipment according to the present invention is pulled out halfway. By pulling out the reactor unit  53  in an arrow  55  direction, a maintenance space  56  is formed inside the main frame. By entering the maintenance space  56 , a worker  54  can perform maintenance work. For example, the worker  54  can perform maintenance work of the load-lock side  62  of the reactor unit  53  pulled out as indicated by a. Or, the worker  54  can perform maintenance work of the AFE side  60 , which is an opposite side of the load-lock side. The worker  54  can perform maintenance work of electrical components, etc. installed on a ceiling portion  61  of the main frame as indicated by b. From outside the main frame, the worker can perform maintenance work of the reactor portion of the reactor unit  53  pulled out as indicated by c. After maintenance work is completed, by putting the reactor unit  53  back to its original position inside the main frame, the maintenance space  56  disappears. 
   Thus, using the semiconductor manufacturing equipment according to the present invention, a maintenance space can be formed only when maintenance work is performed, hence the footprint of the entire equipment can be minimized. Additionally, because maintenance can be performed exceedingly easily and effectively, work hours are shortened and throughput of the semiconductor manufacturing equipment improves. 
     FIG. 7  shows a plan view of the entire equipment and a maintenance method when five units of the semiconductor manufacturing equipment ( 71 ,  72 ,  73 ,  74 , and  75 ) according to the present invention are arranged transversely with no space between the units. In this case, reactor units  72  and  74  for which maintenance work is performed are pulled out completely. As shown in  FIG. 7 , when multiple reactor units are arranged with no space between, maintenance work of two units at both ends ( 71 ,  75 ) can be performed by pulling them out halfway as shown in FIG.  5 . Maintenance work of other three reactor units ( 72 ,  73 , and  74 ) can be performed by pulling them out completely. By pulling out reactor units  72  and  74 , maintenance spaces  76  and  77  are respectively formed. The worker  54  can perform maintenance work of the load-lock side of the reactor units pulled out as indicated by a. The worker  54  can perform maintenance work of the chamber of the adjoining reactor unit from a side as indicated by b. The worker  54  can perform maintenance work of electrical components attached midway in the main frame as indicated by c. The worker  54  can perform maintenance work of the atmosphere robot on the AFE side and other devices as indicated by d. After maintenance work is completed, by putting the reactor units  72  and  74  back to their original positions inside the main frame, the maintenance spaces  76  and  77  disappear. 
   Thus, the semiconductor manufacturing equipment according to the present invention enables arranging of multiple units of semiconductor manufacturing equipment transversely and the footprint of the entire equipment can be minimized. Additionally, because a maintenance space can be formed inside the main frame by selectively pulling out chamber frames for which maintenance work is required, maintenance work can be performed exceedingly easily and effectively. Consequently, work hours required for maintenance are shortened and throughput of the equipment improves. 
   Using the semiconductor manufacturing equipment and the maintenance method according to the present invention, maintenance can be performed exceedingly easily and effectively. 
   Additionally, the semiconductor manufacturing equipment according to the present invention does not have a space for maintenance use and dead space. The footprint of the entire equipment is small and compact. 
   EXPLANATION OF SYMBOLS USED 
   
       
         30  Semiconductor manufacturing equipment 
         31  Main frame 
         32  Modularized semiconductor processing device 
         33  Chamber frame 
         34  Guide component 
         35  Sliding surface 
         36  Wedge-shaped block 
         37  Bearing 
         38  Pressing block 
         39  Caster 
         40  Concave portion 
         41  Concave portion