Patent Description:
The present disclosure relates to substrate processing systems, and more particularly to configurations of substrate processing tools in a substrate processing system.

The background description provided here is for the purpose of generally presenting the context of the disclosure.

A substrate processing system may be used to perform deposition, etching and/or other treatment of substrates such as semiconductor wafers. During processing, a substrate is arranged on a substrate support in a processing chamber of the substrate processing system. Gas mixtures including one or more precursors are introduced into the processing chamber and plasma may be struck to activate chemical reactions.

The substrate processing system may include a plurality of substrate processing tools arranged within a fabrication room. Each of the substrate processing tools may include a plurality of process modules. Typically, a substrate processing tool includes up to <NUM> process modules.

Referring now to <FIG>, a top-down view of an example substrate processing tool <NUM> is shown. The substrate processing tool <NUM> includes a plurality of process modules <NUM>. For example only, each of the process modules <NUM> may be configured to perform one or more respective processes on a substrate. Substrates to be processed are loaded into the substrate processing tool <NUM> via ports of a loading station of an atmosphere-to-vacuum (ATV) transfer module, such as an equipment front end module (EFEM) <NUM>, and then transferred into one or more of the process modules <NUM>. For example, a transfer robot <NUM> is arranged to transfer substrates from loading stations <NUM> to airlocks, or load locks, <NUM>, and a vacuum transfer robot <NUM> of a vacuum transfer module <NUM> is arranged to transfer substrate from the load locks <NUM> to the various process modules <NUM>. Documents <CIT>, <CIT> or <CIT> disclose transfer modules of the prior art.

An atmosphere-to-vacuum (ATV) transfer module for a substrate processing tool is configured as defined in the independent claims. An atmosphere-to-vacuum (ATV) transfer module for a substrate processing tool includes a first side configured to interface with at least one loading station, a transfer robot assembly arranged within the ATV transfer module, and a second side opposite the first side. The transfer robot assembly is configured to transfer substrates between the at least one loading station and at least one load lock arranged between the ATV transfer module and a vacuum transfer module (VTM). The second side is configured to interface with the at least one load lock. The transfer robot assembly is arranged adjacent to the second side, and the at least one load lock extends through the second side into an interior volume of the ATV transfer module, wherein the transfer robot assembly includes a transfer robot platform configured to support a transfer robot, and wherein the transfer robot assembly is configured to (i) raise and lower the transfer robot platform to adjust a position of the transfer robot platform in a vertical direction and (ii) adjust the position of the transfer robot platform in a horizontal direction; wherein the transfer robot assembly includes a first robot alignment arm and a second robot alignment arm configured to vertically and horizontally adjust the position of the transfer robot platform; wherein the transfer robot includes an arm and is configured to fold into a folded configuration having a narrow profile, wherein the arm of the transfer robot comprises an arm segment and an end effector; and wherein the transfer robot assembly occupies less than <NUM>% of an overall depth of the ATV transfer module when the transfer robot is in the folded configuration.

In other features, at least approximately <NUM>% of the at least one load lock is located within the interior volume of the ATV transfer module. At least approximately <NUM>% of the at least one load lock is located within the interior volume of the ATV transfer module. At least approximately <NUM>% of the at least one load lock is located within the interior volume of the ATV transfer module.

In other features, the ATV transfer module corresponds to an equipment front end module (EFEM). The at least one load lock includes a first load lock and a second load lock arranged above the first load lock. The at least one loading station includes a first loading station and a second loading station arranged above the first loading station. The transfer robot assembly is configured to access the first load lock and the second load lock.

In other features, the ATV transfer further includes a lateral rail and a vertical rail mounted on the lateral rail. The transfer robot assembly is mounted on the vertical rail and is configured to raise and lower in a vertical direction on the vertical rail, and the vertical rail is configured to slide in a horizontal direction on the lateral rail. The transfer robot assembly includes two arms, each of the arms includes an arm segment and an end effector, and a length of the end effector is greater than a length of the arm segment. The length of the end effector is twice the length of the arm segment. When the transfer robot assembly is in a folded configuration, the arm segments and the end effectors are coaxial.

In other features, the transfer robot assembly includes a transfer robot platform configured to support a transfer robot. The transfer robot assembly is configured to raise and lower the transfer robot platform to adjust a position of the transfer robot platform in a vertical direction and adjust the position of the transfer robot platform in a horizontal direction. The transfer robot assembly includes a first robot alignment arm and a second robot alignment arm configured to adjust the position of the transfer robot platform. The transfer robot includes an arm having (i) an arm segment and (ii) an end effector.

In other features, a substrate processing tool includes the ATV transfer module and further includes the VTM. The VTM includes a plurality of process modules and the plurality of process modules includes at least three process modules arranged on a first side of the VTM and at least three process modules arranged on a second side of the VTM opposite the first side. The plurality of process modules includes process modules in a vertically stacked configuration.

Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.

The quantity, position, etc. of substrate processing tools within a fabrication room may be constrained by the dimensions and respective configurations of the substrate processing tools. Accordingly, the configurations of the substrate processing tools define a tool footprint, spacing, and/or pitch, which further define a tool density of the fabrication room. Tool density may refer to a number of substrate processing tools and/or process modules per unit area of a fabrication room. Systems and methods according to the principles of the present disclosure provide various substrate processing tool configurations to maximize substrate processing tool density.

For example, an equipment front end module (EFEM) of a substrate processing tool may include one or more transfer robots for transferring substrates between the EFEM and load locks arranged between the EFEM and a vacuum transfer module (VTM). An internal volume of the EFEM must be sufficient to accommodate the transfer robot. Accordingly, the load locks are typically located outside of a footprint of an equipment front end module (EFEM) between the EFEM and the VTM. Systems and methods according to the principles of the present disclosure implement modified airlocks configured to reduce a footprint of a substrate processing tool. In some examples, the EFEM may include a transfer robot having a configuration that allows the airlocks to be located at least partially within the EFEM.

<FIG>, <FIG> show plan views of example configurations of a first substrate processing tool <NUM>-<NUM>, a second substrate processing tool <NUM>-<NUM>, and a third substrate processing tool <NUM>-<NUM> (referred to collectively as substrate processing tools <NUM>) according to the principles of the present disclosure. Each of the processing tools <NUM> includes a modified equipment front end module (EFEM) <NUM> configured to accommodate at least a portion of load locks <NUM>. In other words, instead of being located outside of the EFEM <NUM> in a gap between the EFEM <NUM> and a vacuum transfer module (VTM) <NUM>, the load locks <NUM> extend into an interior of the EFEM <NUM>. For example, at least approximately <NUM>% (e.g., <NUM>-<NUM>%) of the overall external length or volume of the load locks <NUM> may be located within the EFEM <NUM>. In some examples, at least approximately <NUM>% (e.g., <NUM>-<NUM>%) of the overall external length or volume of the load locks <NUM> are located within the EFEM <NUM>. In other examples, at least approximately <NUM>% (e.g., <NUM>-<NUM>%) of the overall external length or volume of the load locks <NUM> is located within the EFEM <NUM>. Accordingly, the EFEM <NUM> can be located closer to the VTM <NUM>, reducing the overall footprint and increasing the pitch of the tools <NUM>. For example, a transfer robot <NUM> of the EFEM <NUM> according to the present disclosure is arranged closer to loading stations <NUM> on a front wall (e.g., a first side) than a back wall <NUM> (e.g., a second side) of the EFEM <NUM> to provide space for the load locks <NUM> to extend into the interior of the EFEM <NUM>. The EFEM <NUM> and the transfer robot <NUM> are described below in more detail in <FIG>. In some examples, the load locks <NUM> may be configured as shown in an alternative arrangement of the tool <NUM>-<NUM> in <FIG>. For example only, the loading stations <NUM> may correspond to front opening unified pods (FOUPs).

As shown, the tools <NUM> include six process modules <NUM>. However, other configurations of the tools <NUM> may include more than six of the process modules <NUM>. For example, a length of the VTM <NUM> may be extended to accommodate additional process modules <NUM>. Similarly, the VTM <NUM> may include vacuum transfer robots <NUM> having various configurations. For example, the tool <NUM>-<NUM> includes three vacuum transfer robots <NUM> and the tool <NUM>-<NUM> includes two vacuum transfer robots <NUM>. In the tools <NUM>-<NUM> and <NUM>-<NUM>, the robots <NUM> are aligned with a center lengthwise axis of the VTM <NUM>. Conversely, the tool <NUM>-<NUM> includes a single vacuum transfer robot <NUM> arranged off-center (i.e. shifted to the right or left toward the process modules <NUM>) relative to the center lengthwise axis of the VTM <NUM>. In other words, a primary pivot point of the robot <NUM> is off-center. Although shown having one or two arms, each of the robots <NUM> and <NUM> may have configurations including one, two, or more arms. In some examples, the robot <NUM> may include two end effectors <NUM> on each of the arms as shown in <FIG>.

The substrate processing tools <NUM> may include one or more storage buffers <NUM> configured to store one or more substrates between processing stages. In some examples, storage buffers <NUM> may be located within the VTM <NUM>. In some examples, one or more of the storage buffers <NUM> may be replaced with process modules or other components.

In some examples, one or more of the EFEM <NUM>, the load locks <NUM>, the VTM <NUM>, and the process modules <NUM> may have a stacked configuration as described below in more detail. For example, each of the process modules <NUM> may correspond to two process modules <NUM> in a vertically stacked configuration (i.e., one process module <NUM> arranged above/below the other), the VTM <NUM> may correspond to two VTMs <NUM> in the vertically stacked configuration, each of the load locks <NUM> may correspond to two load locks <NUM> in the vertically stacked configuration, and each of the loading stations <NUM> may correspond to two loading stations <NUM> in the vertically stacked configuration. A height of the EFEM <NUM> may be increased to allow the robot <NUM> to be raised and lowered to different levels within the EFEM <NUM> to access multiple levels of the loading stations <NUM> and the load locks <NUM>.

<FIG>, <FIG> show an example EFEM <NUM> and transfer robot assembly <NUM> according to the principles of the present disclosure. The assembly <NUM> may be mounted to one or more vertical rails <NUM> within the EFEM <NUM>, which are in turn mounted on a lateral rail <NUM>. The assembly <NUM> is configured to raise and lower in a vertical, Z direction on the vertical rails <NUM>. For example, the assembly <NUM> may be mounted in slots <NUM> in the vertical rails <NUM>. Conversely, the assembly <NUM> is configured to slide in a horizontal, X direction with the vertical rails <NUM> along the horizontal rail <NUM>. In this manner, a position of the assembly <NUM> may be adjusted in the Z direction and the X direction to provide access to load locks <NUM> and loading stations <NUM> at different heights (i.e., levels).

In one example, the transfer robot assembly <NUM> includes two arms <NUM>, each including an arm segment <NUM> and an end effector <NUM>. For example only, the end effector <NUM> may be longer than the arm segment <NUM>. In one example, a length L2 of the end effector <NUM> is twice a length L1 of the arm segment <NUM> (e.g., L2 = - <NUM>*L1). A length L2 of the end effector <NUM> corresponds to a distance between an approximate center of a substrate support end of the end effector <NUM> and a pivot point of the end effector <NUM> (i.e., a pivot point of the end effector <NUM> relative to the arm segment <NUM>. A length L1 of the arm segment <NUM> corresponds to a distance between pivot points of the arm segment <NUM> (i.e., the pivot point of the end effector <NUM> relative to the arm segment <NUM> and a pivot point of the arm segment <NUM> relative to a base of the transfer robot assembly <NUM>. The greater length L2 of the end effector <NUM> relative to the length L1 of the arm segment <NUM> allows the end effector <NUM> to access the load locks <NUM> without requiring the arm segment <NUM> to also enter the load locks <NUM>.

When in a folded configuration as shown, the assembly <NUM> has a relatively narrow profile (e.g., in accordance with dimensions of the substrate being transported) relative to the EFEM <NUM>. Accordingly, the EFEM is configured to accommodate at least a portion of the load locks <NUM>. The assembly <NUM> may include an integrated substrate aligner <NUM>. In this example, the greater length L2 of the end effectors <NUM> allows the end effectors <NUM> to be positioned over the substrate aligner <NUM> when the transfer robot assembly <NUM> is in the folded configuration shown in <FIG>. For example, the relative lengths of the arm segments <NUM> and the end effectors <NUM> allow a relatively linear folded configuration where the arm segments <NUM>, the end effectors <NUM>, and the substrate aligner <NUM> are aligned on a line <NUM> (i.e., coaxial with the line <NUM>).

Each of the arms <NUM> may be mounted in the slot <NUM> of a respective one of the vertical rails <NUM>. For example, the vertical rails <NUM> may move independently of one another. In other words, although shown in a compact arrangement in <FIG>, and <FIG> (i.e., the vertical rails <NUM> are relatively close together), one of the rails <NUM> may be moved to an end of the EFEM <NUM> opposite to the other one of the rails <NUM> as shown in <FIG>. In this manner, the respective arms <NUM> are configured to access different ones of the loading stations <NUM> and/or the load locks <NUM> at the same time. In other examples, the EFEM <NUM> may include only one of the vertical rails <NUM> and a respective one of the arms <NUM>.

In some examples, the additional space within the EFEM <NUM> achieved by the configuration of the transfer robot assembly <NUM> may allow additional substrate processing and transfer system components to be located within the EFEM <NUM>. For example, components including, but not limited to, metrology stations, storage buffers, notch alignment stations, edge ring storage, etc. may be located in the EFEM <NUM>. In one example, when in the folded configuration, the transfer robot assembly <NUM> occupies less than <NUM>% of an overall depth of the EFEM <NUM>.

<FIG> shows a side view of an example substrate processing tool <NUM> in a dual, vertically stacked configuration. The substrate processing tool <NUM> includes an EFEM <NUM> having an extended height to accommodate a transfer robot assembly <NUM> as described above in <FIG>. The transfer robot assembly <NUM> is configured to be raised and lowered on vertical rails <NUM> and a horizontal rail <NUM> to access vertically stacked loading stations <NUM> and load locks <NUM>. The load locks <NUM> are located at least partially within the EFEM <NUM>.

The tool <NUM> includes vertically stacked VTMs <NUM>. Each of the VTMs <NUM> includes one or more vacuum transfer robots <NUM>. The vacuum transfer robots <NUM> are configured to transfer substrates between the load locks <NUM> and vertically stacked process modules <NUM>.

<FIG> shows a plan view of an example one of the load locks <NUM> located within the EFEM <NUM>. As shown, greater than <NUM>% of an overall external length (e.g., a length L from a first outer wall <NUM> to a second outer wall <NUM>) of the load lock <NUM> is located within the EFEM <NUM>. Substrates are transferred from the EFEM <NUM> to the load lock <NUM> (e.g., using the transfer robot assembly <NUM>) via ports <NUM> located inside an interior volume of the EFEM <NUM>. Conversely, substrates are transferred from the load lock <NUM> to the VTM <NUM> via ports <NUM>. As shown, the load lock <NUM> includes two loading stations <NUM>, two of the ports <NUM>, and two of the ports <NUM>.

A valve <NUM> and pump <NUM> may be operated to pump down and maintain the load lock <NUM> at vacuum, purge the load lock <NUM>, etc. In some examples, the valve <NUM> interfaces with the load lock <NUM> on a surface outside of the EFEM <NUM>. In other examples, the valve <NUM> interfaces with the load lock <NUM> on a surface within the EFEM <NUM>.

<FIG> show another example EFEM <NUM> and transfer robot assembly <NUM>. For example, the EFEM <NUM> and the transfer robot assembly <NUM> may be implemented in any of the substrate processing tools <NUM> of <FIG>. The assembly <NUM> may be mounted within a front end region (i.e., a loading station side) of the EFEM <NUM>. For example, the assembly <NUM> may be coupled to a mounting chassis <NUM> arranged in the front end region of the EFEM <NUM>. The assembly <NUM> is configured to both raise and lower a transfer robot platform <NUM> in a vertical, Z direction and adjust a lateral position of the platform <NUM> in a horizontal, X direction. In this manner, a position of the assembly platform <NUM> may be adjusted in the Z direction and the X direction to provide access to load locks <NUM> and loading stations <NUM> at different heights (i.e., levels).

In one example, the transfer robot assembly <NUM> includes two robot alignment arms <NUM> and <NUM> configured to actuate about pivot points <NUM> and <NUM> (which may include corresponding motors) to adjust a position of the platform <NUM>. The platform <NUM> supports a transfer robot <NUM>. The transfer robot <NUM> includes an arm comprising an arm segment <NUM> and an end effector <NUM>. When in a folded configuration as shown, the assembly <NUM> and the transfer robot <NUM> have a relatively narrow profile (e.g., in accordance with dimensions of the substrate being transported) relative to the EFEM <NUM>. Accordingly, the EFEM <NUM> is configured to accommodate at least a portion of the load locks <NUM> in a manner similar to the EFEM <NUM> of <FIG>. In some examples, the platform <NUM> may include an integrated substrate aligner <NUM>. In this example, the end effector <NUM> is positioned over the substrate aligner <NUM> when the transfer robot <NUM> is in the folded configuration shown in <FIG>. The transfer robot <NUM> has a relatively linear folded configuration where the arm segment <NUM>, the end effector <NUM>, and the substrate aligner <NUM> are aligned on a line <NUM> (e.g., coaxial with the line <NUM>).

Although <FIG> and <FIG> show the EFEMs <NUM> and <NUM> arranged to access vertically stacked loading stations and load locks, in other examples the EFEMs <NUM> and <NUM> may be implemented in substrate processing tools that do not include vertically stacked configurations. For example, some substrate processing tools may include loading stations, load locks, and/or process modules that are arranged at a greater height on/within the tool, that have access slots that are arranged higher on the loading station, load lock, and/or process modules, etc..

<FIG> show plan views of example configurations of another substrate processing tool <NUM> according to the principles of the present disclosure. The processing tool <NUM> includes a modified equipment front end module (EFEM) <NUM> configured to accommodate at least a portion of one or more load locks <NUM>. In other words, instead of being located entirely outside of the EFEM <NUM> in a gap between the EFEM <NUM> and a vacuum transfer module (VTM) <NUM>, the load locks <NUM> extend into an interior of the EFEM <NUM>. Accordingly, the EFEM <NUM> can be located closer to the VTM <NUM>, reducing the overall footprint and increasing the pitch of a plurality of the tools <NUM>. The EFEM <NUM> may be configured to include, for example, the transfer robot assembly <NUM> as described in <FIG>, the transfer robot assembly <NUM> as described in <FIG>, etc..

As shown, the tool <NUM> includes ten process modules <NUM>. For example, a length of the VTM <NUM> may be extended to accommodate additional process modules <NUM>. Similarly, the VTM <NUM> may include vacuum one or more transfer robots <NUM> (e.g., transfer robots <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) having various configurations. As shown, the transfer robots <NUM> include one arm <NUM> having three arm segments <NUM> and one end effector <NUM> in each of the configurations. In other configurations, the transfer robots <NUM> may include one, two, or more arms <NUM>. In some examples, the robots <NUM> may include two of the end effectors <NUM> on each of the arms <NUM>.

As shown in <FIG>, the tool <NUM> includes a single vacuum transfer robot <NUM>-<NUM> arranged off-center (i.e. shifted to the right or left toward the process modules <NUM>) relative to the center lengthwise axis of the VTM <NUM>. In other words, a primary pivot point of the robot <NUM>-<NUM> is off-center. The robot <NUM>-<NUM> is positioned and configured to access each of the ten process modules <NUM> and the load lock(s) <NUM>. In configurations where the tool <NUM> includes storage buffers <NUM> and/or storage buffers <NUM>, the robot <NUM>-<NUM> is also configured to access the storage buffers <NUM>/<NUM>.

As shown in <FIG>, the tool <NUM> includes two vacuum transfer robot <NUM>-<NUM> and <NUM>-<NUM> or <NUM>-<NUM> and <NUM>-<NUM>, respectively, arranged off-center (i.e. shifted to the right or left toward the process modules <NUM>) relative to the center lengthwise axis of the VTM <NUM>. The robots <NUM>-<NUM> and <NUM>-<NUM> are positioned and configured to access selected ones of the ten process modules <NUM> and the load lock(s) <NUM>. Conversely, the robots <NUM>-<NUM> and <NUM>-<NUM> are positioned and configured to access others of the ten process modules <NUM>. In configurations where the tool <NUM> includes storage buffers <NUM> and/or storage buffers <NUM>, the robots <NUM>-<NUM> and <NUM>-<NUM> may also be configured to access the storage buffers <NUM>, while both of the robots <NUM>-<NUM> and <NUM>-<NUM> in <FIG> and both of the robots <NUM>-<NUM> and <NUM>-<NUM> in <FIG> are configured to access the storage buffers <NUM>.

For example, as shown in <FIG>, the robot <NUM>-<NUM> is aligned with (e.g., centered on a horizontal axis of) a respective one of the process modules <NUM> while the robot <NUM>-<NUM> is arranged centered between adjacent ones of the process modules <NUM>. Conversely, as shown in <FIG>, each of the robots <NUM>-<NUM> and <NUM>-<NUM> is aligned with a respective one of the process modules <NUM>.

The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims. It should be understood that one or more steps within a method may be executed in different order (or concurrently) without altering the principles of the present disclosure. Further, although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of the disclosure can be implemented in and/or combined with features of any of the other embodiments, even if that combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more embodiments with one another remain within the scope of this disclosure.

Spatial and functional relationships between elements (for example, between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including "connected," "engaged," "coupled," "adjacent," "next to," "on top of," "above," "below," and "disposed. " Unless explicitly described as being "direct," when a relationship between first and second elements is described in the above disclosure, that relationship can be a direct relationship where no other intervening elements are present between the first and second elements, but can also be an indirect relationship where one or more intervening elements are present (either spatially or functionally) between the first and second elements. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean "at least one of A, at least one of B, and at least one of C.

In some implementations, a controller is part of a system, which may be part of the above-described examples. Such systems can comprise semiconductor processing equipment, including a processing tool or tools, chamber or chambers, a platform or platforms for processing, and/or specific processing components (a substrate pedestal, a gas flow system, etc.). These systems may be integrated with electronics for controlling their operation before, during, and after processing of a semiconductor substrate or substrate. The electronics may be referred to as the "controller," which may control various components or subparts of the system or systems. The controller, depending on the processing requirements and/or the type of system, may be programmed to control any of the processes disclosed herein, including the delivery of processing gases, temperature settings (e.g., heating and/or cooling), pressure settings, vacuum settings, power settings, radio frequency (RF) generator settings, RF matching circuit settings, frequency settings, flow rate settings, fluid delivery settings, positional and operation settings, substrate transfers into and out of a tool and other transfer tools and/or load locks connected to or interfaced with a specific system.

Broadly speaking, the controller may be defined as electronics having various integrated circuits, logic, memory, and/or software that receive instructions, issue instructions, control operation, enable cleaning operations, enable endpoint measurements, and the like. The integrated circuits may include chips in the form of firmware that store program instructions, digital signal processors (DSPs), chips defined as application specific integrated circuits (ASICs), and/or one or more microprocessors, or microcontrollers that execute program instructions (e.g., software). Program instructions may be instructions communicated to the controller in the form of various individual settings (or program files), defining operational parameters for carrying out a particular process on or for a semiconductor substrate or to a system. The operational parameters may, in some embodiments, be part of a recipe defined by process engineers to accomplish one or more processing steps during the fabrication of one or more layers, materials, metals, oxides, silicon, silicon dioxide, surfaces, circuits, and/or dies of a substrate.

The controller, in some implementations, may be a part of or coupled to a computer that is integrated with the system, coupled to the system, otherwise networked to the system, or a combination thereof. For example, the controller may be in the "cloud" or all or a part of a fab host computer system, which can allow for remote access of the substrate processing. The computer may enable remote access to the system to monitor current progress of fabrication operations, examine a history of past fabrication operations, examine trends or performance metrics from a plurality of fabrication operations, to change parameters of current processing, to set processing steps to follow a current processing, or to start a new process. In some examples, a remote computer (e.g. a server) can provide process recipes to a system over a network, which may include a local network or the Internet. The remote computer may include a user interface that enables entry or programming of parameters and/or settings, which are then communicated to the system from the remote computer. In some examples, the controller receives instructions in the form of data, which specify parameters for each of the processing steps to be performed during one or more operations. It should be understood that the parameters may be specific to the type of process to be performed and the type of tool that the controller is configured to interface with or control. Thus as described above, the controller may be distributed, such as by comprising one or more discrete controllers that are networked together and working towards a common purpose, such as the processes and controls described herein. An example of a distributed controller for such purposes would be one or more integrated circuits on a chamber in communication with one or more integrated circuits located remotely (such as at the platform level or as part of a remote computer) that combine to control a process on the chamber.

Without limitation, example systems may include a plasma etch chamber or module, a deposition chamber or module, a spin-rinse chamber or module, a metal plating chamber or module, a clean chamber or module, a bevel edge etch chamber or module, a physical vapor deposition (PVD) chamber or module, a chemical vapor deposition (CVD) chamber or module, an atomic layer deposition (ALD) chamber or module, an atomic layer etch (ALE) chamber or module, an ion implantation chamber or module, a track chamber or module, and any other semiconductor processing systems that may be associated or used in the fabrication and/or manufacturing of semiconductor substrates.

Claim 1:
An atmosphere-to-vacuum (ATV) transfer module (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) for a substrate processing tool, the ATV transfer module comprising:
a first side configured to interface with at least one loading station (<NUM>, <NUM>, <NUM>);
a transfer robot assembly (<NUM>) arranged within the ATV transfer module, wherein the transfer robot assembly is configured to transfer substrates between the at least one loading station (<NUM>) and at least one load lock (<NUM>, <NUM>) arranged between the ATV transfer module and a vacuum transfer module (VTM) (<NUM>, <NUM>, <NUM>); and
a second side, opposite the first side, configured to interface with the at least one load lock (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>), wherein the transfer robot assembly is arranged adjacent to the second side, and wherein the at least one load lock (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) extends through the second side into an interior volume of the ATV transfer module (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>);
characterized in that:
the transfer robot assembly (<NUM>) includes a transfer robot platform (<NUM>) configured to support a transfer robot (<NUM>);
the transfer robot assembly is configured to (i) raise and lower the transfer robot platform to adjust a position of the transfer robot platform in a vertical direction and (ii) adjust the position of the transfer robot platform in a horizontal direction;
the transfer robot assembly includes a first robot alignment arm (<NUM>) and a second robot alignment (<NUM>) arm configured to vertically and horizontally adjust the position of the transfer robot platform;
the transfer robot includes an arm (<NUM>) and is configured to fold into a folded configuration having a narrow profile;
the arm of the transfer robot comprises an arm segment (<NUM>) and an end effector (<NUM>); and
the transfer robot assembly occupies less than <NUM>% of an overall depth of the ATV transfer module when the transfer robot is in the folded configuration.