Patent ID: 12217992

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

Typically, a number of different unit operations (e.g., masking, etching, deposition, implanting etc.) are performed in order to fabricate a semiconductor device. The semiconductor wafer that the semiconductor devices are fabricated upon may be transported from unit operation to unit operation during device fabrication. For example, a storage container, such as a front opening unified pod (FOUP) may be used to transport the semiconductor wafers from one unit operation to another. An automated system, such as an automated material handling system (AMHS), may be used to transport the FOUPs containing the wafers to multiple wafer processing apparatuses within the semiconductor fabrication plant for performing different unit operations. Delays in the transporting of wafers to the different processing apparatuses can decrease manufacturing efficiency and increase the cost of goods. Thus, there is a continuing need for further improvements in efficiency of material handling systems, such as automated material handling systems used in semiconductor manufacturing processes. Generally, the structures and methods of the present disclosure may be used to improve the transfer efficiency of an automated material handling system (AMHS), such as an overhead AMHS used in the semiconductor manufacturing industry.

FIG.1is a schematic front view of a portion of a semiconductor fabrication facility, which may also be referred to as a foundry or “fab,” which may include a plurality of semiconductor wafer processing apparatuses110located in a controlled manufacturing environment (e.g., a clean room). Each of the wafer processing apparatuses110may be configured to perform one or more unit operations (e.g., masking, etching, deposition, implanting, etc.) on semiconductor wafers109. The wafers109may be moved to different wafer processing apparatuses110in a pre-determined sequence in order to fabricate integrated circuit (IC) devices on the wafer109. In various embodiments, groups of wafers109may be located within each wafer storage container105, which may be moved to different processing apparatuses110to perform different unit operations on the wafers contained within the wafer storage container105. In various embodiments, the wafer storage containers105may be front opening unified (or universal) pods, which are also known as “FOUPs.” A FOUP is a standardized container used to safely house and transport a plurality of semiconductor wafers (e.g.,25wafers, although more or less wafers may be housed and transported) in a controlled environment. A FOUP may include handles115on either side of the container to enable a user to carry the FOUP and may also include features to enable the FOUP to interface with a load port107of a semiconductor wafer processing apparatus110and to be handled by an automated material handling system100. Other types of wafer storage containers105for semiconductor wafers109are within the contemplated scope of this disclosure.

Referring again toFIG.1, each of the wafer processing apparatuses110may include an interior portion within which environmental conditions may be controlled. A door117may enable wafers109to enter and exit the interior portion of the wafer processing apparatus110. In some embodiments, a robot arm (not shown inFIG.1) may be used to transfer semiconductor wafers109between the wafer storage container105and the interior portion of the wafer processing apparatus110.

A load port107may be configured to receive and support the storage containers105and to provide an interface between the wafer storage container105and the wafer processing apparatus110. The load port107may include a mounting surface104configured to receive and support a storage container105. A base structure106may support the mounting surface104of the load port107above the floor of the manufacturing facility. In some embodiments, the base structure106may support the mounting surface104at a height that facilitates the transfer of wafers between the storage container105and the wafer processing apparatus110. The load port107may include mechanical features (e.g., kinematic pins) that mate with corresponding features of the storage containers105to properly align the storage containers105on the load port107. The load port107may also include a latch or similar mechanism to secure the wafer storage container105onto the load port107. In various embodiments, the load port107may also include sensors to detect when a storage container105is located on the load port107. The load port107may further include an automatic identification and data capture (AIDC) system, such as an RFID reader, to obtain identifying information and optionally additional data from the wafer storage container105. In various embodiments, the load port107may be configured to advance the wafer storage container105towards the wafer processing apparatus110and to open the storage container105so that the wafers109contained within the storage container105may be accessed by the wafer processing apparatus110.

Referring again toFIG.1, the semiconductor fabrication facility may also include an automated material handling system (AMHS)100. The AMHS100may be a computer-controlled automated system for moving wafer storage containers105to different locations in the semiconductor fabrication facility. In the embodiment shown inFIG.1, the AMHS100is an overhead system that includes one or more tracks101that may be suspended from or otherwise mounted to the ceiling of the semiconductor fabrication facility. A plurality of vehicles103, which may be overhead hoist transfer (OHT) vehicles, may be driven along the one or more tracks101.FIG.1depicts three OHT vehicles103that may be driven along the track101in a first direction, hd1. A network of overhead tracks101, such as shown inFIG.1, may extend throughout the semiconductor fabrication facility to enable OHT vehicles103to transfer wafer storage containers105between different locations within the semiconductor fabrication facility.

Each OHT vehicle103may include a hoist mechanism111that may be selectively lowered from the vehicle103to capture a wafer storage container105. In various embodiments, the hoist mechanism111may capture the wafer storage containers105by clamping onto a feature of the wafer storage containers105, such as a flange113located at the top of the storage container105. Once the wafer storage container105has been captured by the hoist mechanism111, the hoist mechanism111and the wafer storage containers105may be retracted into the OHT vehicle103, as shown on the right-hand side ofFIG.1. The OHT vehicle103may then be driven to a different location in the semiconductor fabrication facility, such as the location of another load port107associated with a different wafer processing apparatus110for performing additional unit operation(s) on the wafers109. The OHT vehicle103may deliver the wafer storage container105to the target load port107by lowering the wafer storage containers105onto the load port107using the hoist mechanism111. The OHT vehicle103may then release the wafer storage container105and retract the hoist mechanism111, and may then travel to a different location to pick up another wafer storage container105.

A semiconductor fabrication facility such as shown inFIG.1may also include a communication network that enables the AMHS100to communicate with the load ports107and/or the wafer processing apparatuses110. In various embodiments, the load ports107may send messages to the AMHS100indicating that a wafer storage container105is ready to be picked up by an OHT vehicle103and/or that the load port107is ready to receive a new wafer storage container105for processing by the wafer processing apparatus110.

A deficiency with existing automated material handling systems is that as the number of partially-finished semiconductor wafers or other items of manufacture (also known as “works-in-progress” (WIP)) increases, the material handling system may approach or exceed maximum capacity, leading to a significant decrease in manufacturing efficiency. This is illustrated inFIG.2, which is a plot showing the results of a simulation of OHT event counts vs. the total WIPs undergoing processing in a semiconductor fabrication facility. Each dot inFIG.2represents a randomly-issued call to the AMHS100requesting a transfer of a wafer storage container105(e.g., a drop-off or a pick-up of a wafer storage containers105to or from a load port107). The squares represent “one-time events” (i.e., either a drop-off or a pick-up). The triangles represent “in-and-out” events (i.e., a pick-up of a completed wafer storage container105and a drop-off of a new wafer storage containers105for processing). As shown by the solid lines inFIG.2, the total number of calls to the AMHS is relatively low when the total number of WIPs is low, and increases with increasing WIP volume. In the simulation depicted inFIG.2, as the WIP count approaches 10,000, the AMHS100is operating at or near full capacity. The efficiency of the manufacturing equipment (e.g., the wafer processing apparatuses110) decreases rapidly with an increasing WIP count, as indicated by the dotted lines501,503inFIG.2. This problem is particularly acute for “in-and-out” events (shown by the dotted line501inFIG.2), which require a higher volume of OHT calls and result in significantly lower equipment efficiency than “one-time events” (shown by the dotted line503inFIG.2).

One reason for this is that in an overhead AMHS100such as shown inFIG.1, an “in-and-out” process may include the AMHS100locating an empty OHT vehicle103and transporting the OHT vehicle103to the target load port107to pick up the completed wafer storage containers105, while also including the AMHS100locating and directing a second OHT vehicle103to obtain an additional wafer storage container105containing wafers109ready-for-processing and delivering the new wafer storage container105to the target load port107. With a large volume of WIPs, the corresponding large quantity of calls to the AMHS100can result in frequent delays and “traffic jams” on the AMHS100. This may significantly reduce manufacturing efficiency and throughput, may potentially result in spoilage of inventory, and may increase the per unit manufacturing costs.

Accordingly, various embodiments disclosed herein provide methods and systems for improving the efficiency of an automated material handling system (AMHS). In various embodiments, a positioning apparatus operatively coupled to a load port of a processing apparatus may be configured to remove a first work-in-process from the load port and to move the first work-in-process along a first direction (e.g., a horizontal direction) to displace the first work-in-progress from the load port while a second work-in-progress is transferred to the load port from an AMHS vehicle along a second direction (e.g., a vertical direction) that is perpendicular to the first direction. The first work-in-progress may then be transferred from the positioning apparatus to an AMHS vehicle along the second direction. In various embodiment, the first and second works-in-progress (WIPs) may be semiconductor wafers109located in respective wafer storage containers105(e.g., FOUPs). In various embodiments, a single AMHS vehicle103may be used to both load a work-in-progress onto the load port107for processing and to unload an already-processed work-in-progress from the load port107, which can reduce the transfer time and vehicle traffic on the AMHS, thereby increasing the efficiency of the AMHS.

In another mode of operation, an AMHS vehicle103may transfer works-in-progress to be processed onto the positioning apparatus, which may function as a “buffer” by holding the works-in-progress until the works-in-progress that are currently being processed are transferred to an AMHS vehicle103. Then, the positioning apparatus may transfer the works-in-progress to be processed from the positioning apparatus to the load port107. This may significantly reduce the time required to transfer works-in-progress to the load port, and may also reduce AMHS congestion, resulting in improved manufacturing efficiency and lower cost.

FIGS.3A and3Bare front and side views, respectively, of an exemplary structure of a positioning apparatus200for improving the efficiency of an automated material handling system (AMHS)100, such as an overhead AMHS100used in a manufacturing facility, such as a semiconductor fabrication facility, according to a first embodiment of the present disclosure. Referring toFIGS.3A and3B, the positioning apparatus200includes a pair of support rods201located adjacent to a load port107. The support rods201may be mounted to the sides of the base structure106of the load port107as shown inFIGS.3A and3B. Alternatively, the support rods201may be mounted to a different supporting structure, such as the floor of the semiconductor fabrication facility or to the processing apparatus110. The support rods201may be mounted such that they are pivotable with respect to the load port107via a pivot joint205, as shown inFIG.3B. A pivot drive system210may drive the pivoting motion of the support rods201with respect to the load port107. A vertical translation mechanism208may enable the support rods201to move vertically with respect to the load port107. Connected to the upper ends of each of the support rods201may be retractable hooks203. The retractable hooks203may be referred to as a support element that is configured to support the wafer storage containers105that transport the works-in-progress to the load port107.FIG.3Aillustrates the retractable hooks203in an extended position, such that the upper surface of each retractable hook203is located directly below a portion of a wafer storage container105located on the load port107. The wafer storage container105may include a plurality of works-in-progress (WIPs), which may be semiconductor wafers109. The WIPs may be processed by a processing apparatus110that may be associated with the load port107. In various embodiments, the wafer storage container105may be a semiconductor wafer storage container, such as a FOUP. The upper surfaces of the retractable hooks203may be located below the handles115of the wafer storage container105when the retractable hooks203are in an extended position. The retractable hooks203may be connected to the respective support rods201by a pivot joint207that enables the retractable hooks203to pivot from an extended position as shown inFIGS.3A and3Bto a retracted position (seeFIGS.9A and9B). In various embodiments, the first embodiment positioning apparatus200including the support rods201, vertical translation mechanism208, and retractable hooks203, may be coupled to and supported by the load port107. In various embodiments, the first embodiment positioning apparatus200may also be operatively coupled to the load port107, such that the load port107may control the first embodiment positioning apparatus200to perform operations related to the loading of wafer storage containers105onto the load port107and the unloading of wafer storage containers105from the load port107.

FIGS.4A-10Bare sequential front and side views, respectively, of the first embodiment positioning apparatus200shown inFIGS.3A and3Billustrating an exemplary process for unloading a first wafer storage container105A from a load port107and loading a second wafer storage container105B on the load port107(i.e., an “in-and-out” event) according to an embodiment of the disclosure.FIG.30is a flowchart illustrating a method400of processing semiconductor wafers that includes removing a first wafer storage container105A from a load port107and loading a second wafer storage container105B on the load port107(i.e., an “in-and-out” event) according to an embodiment of the disclosure. Referring toFIGS.3A-3B and4A-4Band step402of method400, when unloading (i.e., removing) a first wafer storage container105A from the load port107, the vertical translation mechanism208of the first embodiment positioning apparatus200may translate the support rods201vertically upwards from the first position shown inFIGS.3A and3Bto the second position shown inFIGS.4A and4B. In various embodiments, the vertical translation mechanism208may include a motor and a linear actuator (e.g., belt drive, lead screw, ball screw, rack and pinion, etc.) coupled to the support rods201that translate the support rods201vertically with respect to the load port107. As the support rods201move vertically upwards from the position shown inFIGS.3A and3B, the upper surfaces of the retractable hooks203engage the handles115of the first wafer storage container105A located on the load port107. As the support rods201continue to translate vertically upwards, the retractable hooks203remove the first wafer storage container105A, including at least one semiconductor wafer contained therein, from the load port107by lifting the first wafer storage container105A off of the mounting surface104of the load port107. The first wafer storage container105A may then be supported by the retractable hooks203. The vertical translation mechanism208may continue to translate the retractable hooks203in a vertically upward direction to raise the first wafer storage container105A to the position shown inFIGS.4A and4B. Although in the embodiment shown inFIGS.4A and4B, the retractable hooks203engage the handles115of the first wafer storage container105A, it will be understood that the retractable hooks203may engage with any part of the first wafer storage container105A that enables the retractable hooks203to lift the first wafer storage container105A from the load port107.

Referring again toFIGS.4A and4B, an OHT vehicle103is shown carrying a second wafer storage container105B containing WIPs (e.g., semiconductor wafers) for processing by the processing apparatus110. In various embodiments, when the processing of the WIPs of the first wafer storage container105A is complete, the load port107may issue a call to the AMHS100to retrieve the first wafer storage container105A and load a second wafer storage container105B onto the load port107. The load port107may also direct the support rods201and retractable hooks203to raise the first wafer storage container105A to the position shown inFIGS.4A and4Bwhile the load port107awaits the arrival of the OHT vehicle103carrying the second wafer storage container105B. Alternatively, the first wafer storage container105A may not be raised until the OHT vehicle103carrying the second wafer storage container105B arrives at the load port107.

FIGS.5A and5Bare front and side views, respectively, of the first embodiment positioning apparatus200showing the first wafer storage container105A in a raised position and moved horizontally with respect to the load port107. Referring toFIGS.5A and5Band step404of method400, the pivot drive mechanism210may pivot the support rods201and retractable hooks203on the pivot joint205with respect to the load port107. The pivoting motion of the support rods201and retractable hooks203causes the first wafer storage container105A to move in a first direction, which may be a horizontal direction (i.e., parallel to the direction of arrow hd2) with respect to the load port107, as shown inFIG.5B. A motorized system, such as a rotary drive system210, may drive the pivoting motion of the support rods201and the retractable hooks203with respect to the load port107.

FIGS.6A and6Bare front and side views, respectively, of the first embodiment apparatus200showing the first wafer storage container105A in a raised position and moved horizontally with respect to the load port107while a second wafer storage container105B may be loaded onto the load port107by the hoist mechanism111of the OHT vehicle103. Referring toFIGS.6A and6Band step406of method400, because the first wafer storage container105A may be displaced from the load port107along a first direction (i.e., a horizontal direction) by the pivoting motion of the support rods201and retractable hooks203, the hoist mechanism111of the OHT vehicle103may transfer the second wafer storage container105B, including at least one second work-in-progress contained therein, to the load port107along a second direction (i.e., a vertical direction) that is perpendicular to the first direction. As shown inFIGS.6A and6B, the second wafer storage container105B may be lowered vertically onto the mounting surface104of the load port107by the hoist mechanism111without being obstructed by the first wafer storage container105A.

FIGS.7A and7Bare front and side views, respectively, of the first embodiment positioning apparatus200showing the first wafer storage container105A in a raised position and moved horizontally over the second wafer storage container105B by the pivoting motion of the support rods201and the retractable hooks203. Referring toFIGS.7A and7B, the support rods201and retractable hooks203may be pivoted on the pivot joints205back to the position ofFIGS.5A and5Bcausing the first wafer storage container105A to move in a horizontal direction (i.e., parallel to the direction of arrow hd2) so that the first wafer storage container105A may be located above the upper surface of the second wafer storage container105B that has been loaded onto the load port107.

Referring again toFIGS.7A and7B, an empty OHT vehicle103positioned over the load port107may lower its hoist mechanism111to capture the first wafer storage container105A for transport of the first wafer storage container105A to another location in the semiconductor fabrication facility.

FIGS.8A and8Bare front and side views, respectively, of the first embodiment positioning apparatus200showing the second wafer storage container105B loaded onto the load port107and the first wafer storage container105A raised to the OHT vehicle103. Referring toFIGS.8A and8Band step406of method400, the first wafer storage container105A, including at least one first work-in-progress contained therein, may be transferred from the first embodiment positioning apparatus200to the OHT vehicle103along the second (i.e., vertical) direction. In various embodiments, the empty OHT vehicle103that picks up the first wafer storage container105A from the load port107may be the same OHT vehicle103that delivered the second wafer storage container105B to the load port107. Thus, by utilizing a positioning apparatus200according the first embodiment of the present disclosure, a single OHT vehicle103may be used to complete an “in-and-out” event at the load port107. This may result in a significant time savings and may improve the overall manufacturing efficiency of the fabrication facility.

FIGS.9A and9Bare front and side views, respectively, of the first embodiment positioning apparatus200showing the support rods201and retractable hooks203translated vertically downward with respect to the load port107by the vertical translation mechanism208. Referring toFIGS.9A and9B, as the support rods201and retractable hooks203translate vertically downward, the lower surfaces of the retractable hooks203contact the upper surfaces of the handles115of the second wafer storage container105B. The retractable hooks203may pivot on the pivot joints207from an extended position to a retracted position as shown inFIGS.9A and9B. In various embodiments, the retractable hooks203may be biased into the extended position by a spring mechanism. As the support rods201are translated downward, the force exerted on the retractable hooks203by the handles115of the second wafer storage container105may be sufficient to overcome the spring bias force and cause the retractable hooks203to pivot to a retracted position. This may enable the hooks203to be lowered below the height of the handles115of the second wafer storage container105B.

FIGS.10A and10Bare front and side views, respectively, of the first embodiment positioning apparatus200showing the support rods201and the retractable hooks203returned to their original position shown inFIGS.3A and3B. In embodiments, the bias force of the spring(s) may cause the retractable hooks203to return to an extended position once they are lowered beneath the handles115of the second wafer storage container105B, such that the upper surfaces of the retractable hooks203are located directly beneath the handles115of the second wafer storage container105B. When the support rods201and retractable hooks203are fully lowered as shown inFIGS.10A and10B, the positioning apparatus200may be used to unload the second wafer storage container105B from the load port107and to load an additional wafer storage container105(not shown) onto the load port107via the process shown and described above with reference toFIGS.4A-10B.

Although the first embodiment positioning apparatus200has been described above as including spring-biased retractable hooks203that engage with the handles115of a wafer storage container105, such as a FOUP, to lift the wafer storage container105from the load port107, it will be understood that other configurations are within the contemplated scope of disclosure. For example, rather than spring-biased retractable hooks203, the retractable hooks203may include a motorized system configured to pivot the hooks203into either an extended position (as shown inFIGS.3A-8B and10A-10B) or a retracted position (as shown inFIGS.9A and9B). Alternatively, the retractable hooks203may be designed to return to an extended position under force of gravity, without requiring a spring bias mechanism, once the retractable hooks203are lowered below the height of the handles115of the wafer storage container105. Furthermore, although the first embodiment positioning apparatus200shown inFIGS.3A-10Bincludes retractable hooks203having an upper surface that engages with the underside of the handles115of the wafer storage container105, as noted above the retractable hooks203may engage with any feature of the wafer storage container105that enables the positioning apparatus200to lift the wafer storage container105from the load port107and move the wafer storage container105in a horizontal direction relative to the load port107. For example, the retractable hooks203may be configured to selectively clamp onto side surfaces of the wafer storage container105in order to lift the wafer storage container105. The retractable hooks203may then retract away from the side surfaces of the wafer storage container105as the support rods201and retractable hooks203are lowered back to their initial position.

A first embodiment positioning apparatus200according to the present disclosure may provide significant cost savings and efficiency improvements for an AMHS100. The Delivery Time Accuracy-Out (DTA-OUT) in an AMHS100system such as shown and described above may be defined as the time between when a request is made to the AMHS100to pick up a wafer storage container105from the load port107and when the wafer storage container105is actually picked up from the load port107by the AMHS vehicle103. In a conventional overhead AMHS100system such as shown and described with reference toFIG.1, the average DTA-OUT may be on the order of ˜55 seconds. In comparison, an AMHS utilizing a first embodiment positioning apparatus200according to the present disclosure may have an average DTA-OUT of ˜10 seconds. In various embodiments, an AMHS utilizing a first embodiment apparatus200may have an average DTA-OUT that is at least 50%, such as at least 75%, including more than 80% lower than the average DTA-OUT of a conventional AMHS.

Furthermore, by utilizing a first embodiment apparatus200according to the present disclosure, the total event count of the AMHS100may be reduced by at least about 20%, including by 30% or more. This may provide significant cost savings, including up to ⅓ of the cost or more for an overhead AMHS.

FIGS.11A,11B and11Care front, side and top views, respectively, of an exemplary structure of a positioning apparatus300for improving the efficiency of an automated material handling system (AMHS)100, such as an overhead AMHS100used in a semiconductor manufacturing facility, according to a second embodiment of the present disclosure. Referring toFIGS.11A and11B, the second embodiment positioning apparatus300includes a support tray301that may be coupled to and supported by at least one vertical support307. The support tray301may be referred to as a support element that is configured to support the wafer storage containers105that transport the works-in-progress to the load port107. In the embodiment shown inFIGS.11A and11B, the support tray301is supported by a pair of vertical supports307, although it will be understood that the support tray301may be supported by more than two vertical supports307or by a single vertical support307. The support tray301and the at least one vertical support307may be mounted to a load port107as shown inFIGS.11A and11B. Alternatively, the support tray301and the at least one vertical support307may be mounted to a different supporting structure, such as the floor of the semiconductor manufacturing facility or to the processing apparatus110.

The second embodiment positioning apparatus300may also include a vertical translation mechanism303that enables the support tray301to move vertically with respect to the load port107. In the embodiment shown inFIGS.11A and11B, the vertical translation mechanism303may move both the support tray301and the at least one vertical support307vertically with respect to the load port107. In an alternative embodiment, at least one vertical support307may be stationary and the vertical translation mechanism303may move the support tray301vertically with respect to the load port107and the at least one vertical support307.

The second embodiment positioning apparatus300may also include a horizontal positioning mechanism305that enables the support tray301to move in a horizontal direction, parallel to the direction of arrow hd2, with respect to the load port107and the at least one vertical support307. In embodiments, the support tray301may move in a horizontal direction between a first position, in which the support tray301is located over an upper surface (e.g., mounting surface104) of the load port107as shown inFIG.11B, and a second position in which the support tray301may be laterally displaced from the load port107such that it is not located over the upper surface (e.g., mounting surface104) of the load port107(i.e., as shown inFIGS.13B,14B,15B,17B,18B,22B,23B,24B,25B and28B). In some embodiments, the horizontal positioning mechanism305may move the support tray301in a horizontal direction by translating the support tray301along a direction that is parallel to the direction of arrow hd2. Alternatively, or in addition, in some embodiments the horizontal positioning mechanism305may move the support tray301in a horizontal direction by pivoting or rotating the support tray301in a plane that is parallel to the direction of arrow hd2.

The vertical translation mechanism303and the horizontal positioning mechanism305may each include a motor and a linear actuator (e.g., belt drive, lead screw, ball screw, rack and pinion, etc.) that may move the support tray301in vertical and horizontal directions, respectively, relative to the load port107. In various embodiments, the second embodiment positioning apparatus300including the support tray301, the at least one vertical support(s)307, the vertical translation mechanism303, and the horizontal positioning mechanism305, may be coupled to and supported by the load port107. In various embodiments, the second embodiment positioning apparatus300may also be operatively coupled to the load port107, such that the load port107may control the second embodiment positioning apparatus300to perform operations related to the loading of wafer storage containers105(e.g., first wafer storage container105A and second wafer storage container105B) onto the load port107and the unloading (i.e., removing) of wafer storage containers105from the load port107.

Referring toFIG.11C, an exemplary structure of a support tray301of the second embodiment positioning apparatus300is shown in a top view. The support tray301may include a flat surface309that surrounds an open region310on three-sides. Side walls308may optionally extend around three sides of the flat surface309. The support tray301may also include at least one groove or slot311through which the at least one vertical support307may extend. The support tray301may move horizontally in the direction of arrow hd2with respect to the at least one vertical support307. The flat surface309of the support tray301may be slidable beneath a portion of a wafer storage container105, such as a FOUP. The support tray301may then be moved vertically (i.e., into and out of the page inFIG.11C) to raise and lower the storage container105, similar to the operation of a forklift or pallet jack. The support tray301may also move horizontally with respect to the at least one vertical support307to move the wafer storage container105horizontally along the direction of arrow hd2with respect to a load port107. The open region310of the support tray301may enable the wafer storage container105to be vertically lowered to engage with a mounting surface104(e.g., a kinematic plate) of the load port107to load the wafer storage container105onto the load port107.

FIGS.12A-19Bare sequential front and side views, respectively, of the second embodiment positioning apparatus300shown inFIGS.11A-11Cillustrating an exemplary process for unloading a first wafer storage container105A from a load port107and loading a second wafer storage container105B on the load port107(i.e., an “in-and-out” event) according to an embodiment of the disclosure. Reference is also made again to the flowchart ofFIG.30illustrating a method400of processing semiconductor wafers that includes unloading (i.e., removing) a first wafer storage container105A from a load port107and loading a second wafer storage container105B on the load port107(i.e., an “in-and-out” event) according to an embodiment of the disclosure. Referring toFIGS.11A-11B, a first wafer storage container105A is shown located on the load port107with the support tray301located over the upper surface of the load port107and below a portion of the first wafer storage container105A. Referring toFIGS.12A and12Band to step402of method400, the vertical translation mechanism303may move the support tray301vertically upwards to lift the first wafer storage container105A off the surface of the load port107, thereby removing the first wafer storage container105A from the load port107. An OHT vehicle103is shown carrying a second wafer storage container105B containing WIPs for processing by a processing apparatus110associated with the load port107. In various embodiments, the first wafer storage container105A and the second wafer storage container105B may contain semiconductor wafers109for processing by a wafer processing apparatus110.

In various embodiments, when the processing of the WIPs of the first wafer storage container105A is complete, the load port107may issue a call to the AMHS100to retrieve the first wafer storage container105A from the load port107and load a second wafer storage container105B onto the load port107. The load port107may also direct the vertical translation mechanism303to raise the first wafer storage container105A to the position shown inFIGS.12A and12Bwhile the load port107awaits the arrival of the OHT vehicle103carrying the second wafer storage container105B. Alternatively, the first wafer storage container105A may not be raised until the OHT vehicle103carrying the second wafer storage container105B arrives at the load port107.

FIGS.13A and13Bare front and side views, respectively, of the second embodiment positioning apparatus300showing the support tray301and the first wafer storage container105A moved horizontally with respect to the load port107. Referring toFIGS.13A and13B, and step404of method400, after the first wafer storage container105A is lifted off the load port107, the horizontal positioning mechanism305may move the support tray301with respect to the vertical supports307. This causes the first wafer storage container105to move in a first direction, which may be a horizontal direction (i.e., parallel to the direction of arrow hd2) with respect to the load port107. The support tray301and the first wafer storage container105A may be laterally displaced from the load port107such that the support tray301and the first wafer storage container105A are not located over an upper surface (e.g., mounting surface104) of the load port107.

FIGS.14A and14Bare front and side views, respectively, of the second embodiment positioning apparatus300showing the first wafer storage container105A moved horizontally with respect to the load port107while a second wafer storage container105B may be loaded onto the load port107by the hoist mechanism111of the OHT vehicle103. Referring toFIGS.14A and14Band step406of method400, because the first wafer storage container105A may be displaced from the load port107along a first direction (i.e., a horizontal direction) by the horizontal movement of the support tray301, the hoist mechanism111of the OHT vehicle103may transfer the second wafer storage container105B, including at least one work-in-progress contained therein, to the load port along a second direction (i.e., a vertical direction) that is perpendicular to the first direction. As shown inFIGS.14A and14B, the second wafer storage container105B may be lowered vertically onto the mounting surface104of the load port107by the hoist mechanism111without being obstructed by the first wafer storage container105A.

FIGS.15A and15Bare front and side views, respectively, of the second embodiment positioning apparatus300showing the first wafer storage container105A moved horizontally with respect to the load port107and vertically raised above the load port107and an upper surface of the second wafer storage container105B. Referring toFIGS.15A and15B, the vertical translation mechanism303may translate the support tray301and the first wafer storage container105A vertically upwards until the lower surfaces of the support tray301and first wafer storage container105A may be raised above the height of the upper surface of the second wafer storage container105B located on the load port107. In some embodiments, the horizontal translation of the support tray301and the first wafer storage container105A shown inFIGS.14A and14Bmay occur simultaneously with the vertical translation of the support tray301and the first wafer storage container105A such that when the OHT vehicle103has finished delivering the second wafer storage container105B and has retracted the hoist mechanism111, the apparatus300may be in the configuration shown inFIGS.15A and15B.

FIGS.16A and16Bare front and side views, respectively, of the second embodiment positioning apparatus300showing the first wafer storage container105A in a raised position and moved horizontally over an upper surface of the second wafer storage container105B by a horizontal movement of the support tray301. Referring toFIGS.16A and16B, the horizontal positioning mechanism305may move the support tray301in a horizontal direction parallel to the direction of arrow hd2to move the support tray301and the first wafer storage container105A over the upper surface of the second wafer storage container105B and the load port107.

Referring again toFIGS.16A and16B, an empty OHT vehicle103positioned over the load port107may lower its hoist mechanism111to capture the first wafer storage container105A for transport of the first wafer storage container105A to another location in the semiconductor fabrication facility. Referring toFIGS.16A and16Band step406of method400, the first wafer storage container105A, including at least one first work-in-progress contained therein, may be transferred from the support tray301to the OHT vehicle103along the second (i.e., vertical) direction. In various embodiments, the empty OHT vehicle103that picks up the first wafer storage container105A from the load port107may be the same OHT vehicle103that delivered the second wafer storage container105B to the load port107. Thus, by utilizing an apparatus300according the second embodiment of the present disclosure, a single OHT vehicle103may be used to complete an “in-and-out” event at the load port107. This may result in a significant time savings and may improve the overall manufacturing efficiency of the fabrication facility.

FIGS.17A and17Bare front and side views, respectively, of the second embodiment positioning apparatus300showing the first wafer storage container105A located in an OHT vehicle103and the support tray301moved horizontally with respect to the load port107. Referring toFIGS.17A and17B, the horizontal positioning mechanism305may move the support tray301in a horizontal direction parallel to the direction of arrow hd2to laterally displace the support tray301from the upper surface of the second wafer storage container105B and the load port107.

FIGS.18A and18Bare front and side views, respectively, of the second embodiment positioning apparatus300showing the support tray301in a vertically lowered position and laterally displaced from the second wafer storage container105B and the load port107. Referring toFIGS.18A and18B, the vertical translation mechanism303may translate the support tray301in vertically downward direction. The support tray301may remain laterally displaced from the second wafer storage container105B so that the second wafer storage container105B does not obstruct the support tray301as it is lowered. The support tray301may be lowered to a height that is above the upper surface of the load port107and below a portion of the second wafer storage container105B.

FIGS.19A and19Bare front and side views, respectively, of the second embodiment positioning apparatus300showing the support tray301moved horizontally such that the support tray301is located above an upper surface of the load port107and below a portion of the second wafer storage container105B. Referring toFIGS.19A and19B, the horizontal positioning mechanism305may move the support tray301in a horizontal direction parallel to the direction of arrow hd2such that the support tray301may slide between the upper surface of the load port107and a portion of the second wafer storage container105B. The second embodiment positioning apparatus300may thus return to the configuration shown inFIGS.11A and11B(albeit with the second wafer storage container105B in place of the first wafer storage container105A). The second embodiment positioning apparatus300may then be used to unload the second wafer storage container105B from the load port107and to load an additional wafer storage container105(not shown) onto the load port107via the process shown and described above with reference toFIGS.12A-19B.

A second embodiment positioning apparatus300according to the present disclosure may provide significant cost savings and efficiency improvements for an AMHS100. In various embodiments, an AMHS utilizing a second embodiment positioning apparatus300to perform “in-and-out” events utilizing a process such as shown inFIGS.12A-19Bmay have an average DTA-OUT of about 10 seconds, in comparison to a conventional AMHS system in which the DTA-OUT may average ˜55 seconds. In various embodiments, an AMHS utilizing a second embodiment positioning apparatus300may have an average DTA-OUT that is at least 50%, such as at least 75%, including more than 80% lower (e.g., 80-90% lower) than the average DTA-OUT of a conventional AMHS. Furthermore, by utilizing a second embodiment positioning apparatus300as shown inFIGS.12A-19B, the transfer efficiency of the AMHS100may improve by at least about 20%, including by at least 30%, relative to a conventional AMHS. This may provide significant cost savings, including up to ⅓ of the cost or more for an overhead AMHS.

FIGS.20A-29Bare sequential front and side views of the second embodiment positioning apparatus300shown inFIGS.11A-11Cillustrating an alternative process for unloading a first wafer storage container105A from a load port107and loading a second wafer storage container105B on the load port107according to an embodiment of the disclosure.FIG.31is a flowchart illustrating a method500of processing semiconductor wafers that includes receiving, on a positioning apparatus300, a second wafer storage container105B from a vehicle103of an AMHS100while a first wafer storage container105A is located on a load port107, and using the positioning apparatus300to load the second wafer storage container105B onto the load port107when the first wafer storage container105A is transferred from the load port107to a vehicle103of the AMHS100. Referring toFIGS.20A-29B, the alternative embodiment process may utilize the support element (e.g., support tray301) of the second embodiment positioning apparatus300as a “buffer” for holding a second wafer storage container105B containing WIPs (e.g., semiconductor wafers) to be processed while a first wafer storage container105A may be loaded onto the load port107for processing. The alternative embodiment process may further reduce the time required for loading of wafer storage containers105at the load port107and may also reduce OHT vehicle103congestion on the AMHS100, thus providing increased manufacturing efficiency.

FIGS.20A and20Bare front and side views, respectively, of the second embodiment positioning apparatus300showing a first wafer storage container105A loaded onto the load port107and the support tray301located over an upper surface of the first wafer storage container105A. The first wafer storage container105A may contain a first group of WIPS (e.g., semiconductor wafers109A) that are currently undergoing processing operations by the processing apparatus110associated with the load port107. Referring toFIGS.20A and20B, an OHT vehicle103is shown above the load port107carrying a second wafer storage container105B containing a second group of WIPs (e.g., semiconductor wafers109B). The second group of WIPs may be ready for processing by the processing apparatus110.

In embodiments, the AMHS100may deliver the second wafer storage container105B to the load port107in response to a request from the load port107. However, in various embodiments, the load port107does not need to wait until processing is finished on the first group of WIPs from the first wafer storage container105A before requesting delivery of the second wafer storage container105B by the AMHS100. In various embodiments, the load port107may issue the request for a second wafer storage container105B at any time during the processing of the WIPs from the first wafer storage container105A. Further, because the WIPs from the second wafer storage container105B will typically not need to be processed immediately upon their delivery to the load port107, the load port107may issue the request for the second wafer storage container105B with a lower priority. Thus, if the AMHS100is currently handling a large quantity of requests, such that there is a shortage of available OTS vehicles103and/or a large volume of traffic on the overhead track system101, when the request to deliver the second wafer storage container105B is received, the AMHS100may delay responding to this request until there is less traffic on the overhead track system101and/or a sufficient number of OTS vehicles103available to carry out the request. However, any such delay may not affect processing time if the WIPs from the first wafer storage container105A are still being processed when the second wafer storage container105B may be delivered to the load port107.

FIGS.21A and21Bare front and side views, respectively, of the second embodiment positioning apparatus300showing the second wafer storage container105B lowered onto the support tray301by the hoist mechanism111of the OHT vehicle103. Referring toFIGS.21A and21Band step502of method500, a support element (i.e., support tray301) of the second embodiment positioning apparatus300may receive the second wafer storage container105B while the first wafer storage container105A is located on the load port107. As discussed above, the second wafer storage container105B may be delivered to the second embodiment positioning apparatus300associated with load port107at any time while the WIPs from the first wafer storage container105A are still being processed by the processing apparatus110. The second embodiment positioning apparatus300may utilize the support tray301as a “buffer” for the second wafer storage container105B while the WIPs from the first wafer storage container105A are being processed. In various embodiments, the OHT vehicle103that delivers the second wafer storage container105B to the support tray301may be free to perform other tasks and may not wait for the first wafer storage container105A to be ready to be picked up.

FIGS.22A and22Bare front and side views, respectively, of the second embodiment positioning apparatus300showing the support tray301and the second wafer storage container105B moved laterally relative to the load port107and the first wafer storage container105A. Referring toFIGS.22A and22B, the horizontal positioning mechanism305may translate the support tray301in a horizontal direction parallel to the direction of arrow hd2to laterally displace the support tray301and the second wafer storage container105B from the first wafer storage container105A and the load port107. In embodiments, the support tray301and the second wafer storage container105B may be moved to the position shown inFIGS.22A and22Bwhen the WIPs from the first wafer storage container105A may be finished processing in order to allow the first wafer storage container105A to be picked up by an OHT vehicle103.

FIGS.23A and23Bare front and side views, respectively, of the second embodiment positioning apparatus300showing the first wafer storage container105A being removed from the load port107by the hoist mechanism111of an OHT vehicle103. While the first wafer storage container105A is being picked up by the OHT vehicle103, the support tray301and the second wafer storage container105B may remain in the laterally-displaced position ofFIGS.22A and22Bso as not to obstruct the hoist mechanism111and the first wafer storage container105A as the first wafer storage container105A is unloaded from the load port107.

FIGS.24A and24Bare front and side views, respectively, of the second embodiment positioning apparatus300showing the first wafer storage container105A located in the OHT vehicle103. In various embodiments, the load port107may issue a call to the AMHS100to send an OHT vehicle103to retrieve the first wafer storage container105A when the processing of the first wafer storage container105A is completed. However, the load port107does not need to request delivery of a new wafer storage container105because the second wafer storage container105B containing ready-for-processing WIPs has already been delivered to the support tray301.

FIGS.25A-27Bare sequential front and side views of the second embodiment positioning apparatus300illustrating the process of loading the second wafer storage container105B onto the load port107according to an embodiment. Referring toFIGS.25A and25B, the vertical translation system303may translate the support tray301in a vertically downward direction to lower the second wafer storage container105B towards the upper surface of the load port107. In some embodiments, the vertical translation of the support tray301and the second wafer storage container105B shown inFIGS.25A and25Bmay occur prior to the first wafer storage container105A being transferred to the OHT vehicle103as shown inFIGS.23A-24B. The support tray301may be moved in a vertically downward direction while the support tray301and the second wafer storage container105B are laterally displaced from the first wafer storage container105A to lower the second wafer storage container105B such that at least a portion of the second storage container105B is laterally adjacent to the first wafer storage container105A located on the load port107.

Referring toFIGS.26A and26B, and step504of method500, after the first wafer storage container105A is removed from the load port107by the OHT vehicle103, the horizontal positioning system303may move the support tray301in a first direction (e.g., a horizontal direction parallel to the direction of arrow hd2) to move the second wafer storage container105B over the upper surface of the load port107. In some embodiments, the vertical translation of the support tray301and the second wafer storage container105B shown inFIGS.25A and25Bmay occur simultaneously with the horizontal movement of the support tray301and the second wafer storage container105B shown inFIGS.26A and26B. Alternatively, the vertical translation and the horizontal movement may occur sequentially, in either order. In the configuration shown inFIGS.26A and26B, the support tray301may position the second wafer storage container105B so that the second wafer storage container105B is aligned over the upper surface (e.g., mounting surface104) of the load port107.

FIGS.27A and27Bare front and side views, respectively, of the second embodiment positioning apparatus300showing the support tray lowering the second wafer storage container105B onto the upper surface of the load port107. Referring toFIGS.27A and27B, and step506of method500, the vertical translation system303may translate the support tray301in a second direction (i.e., a vertically downward direction), perpendicular to the first direction, to load the second wafer storage container105B onto the load port107. In various embodiments, the second wafer storage container105B may be lowered such that features on the lower surface of the second wafer storage container105B may engage with corresponding mating features of the upper surface (i.e., the mounting surface104) of the load port107. After the second wafer storage container105B is lowered onto the load port107, the support tray301may be located between the upper surface of the load port107and a portion of the second wafer storage container105B.

FIGS.28A and28Bare front and side views, respectively, of the second embodiment positioning apparatus300showing the support tray301moved in vertical and horizontal directions after the second wafer storage container105B is loaded onto the load port107. In various embodiments, the horizontal positioning mechanism305may move the support tray301in a horizontal direction to cause the support tray301to slide out from between the upper surface of the load port107and the second wafer storage container105B. Then, the vertical drive mechanism303may translate the support tray301in a vertically upward direction along the side of second wafer storage container105B, as shown inFIGS.28A and28B. The vertical drive mechanism303may continue to translate the support tray301in a vertically upward direction until the support tray301is at a height that is greater than a height of the upper surface of the second wafer storage container105B (seeFIGS.29A and29B) in preparation to receive delivery of a third wafer storage container105C (not shown) via an OHT vehicle103.

FIGS.29A and29Bare front and side views, respectively, of the second embodiment positioning apparatus300showing the support tray301located over an upper surface of the second wafer storage container105B and a third wafer storage container105C lowered onto the support tray301by the hoist mechanism111of the OHT vehicle103. In embodiments, the vertical drive mechanism303and the horizontal positioning mechanism305may return the support tray301to the position shown inFIGS.20A and20B, such that the support tray301may be located over the upper surface of the second wafer storage container105B and the load port107. An OHT vehicle103may then deliver a third wafer storage container105C onto the support tray301, as shown inFIGS.29A and29B. The second embodiment apparatus300may utilize the support tray301as a “buffer” for the third wafer storage container105C while the WIPs from the second wafer storage container105B are being processed. When the WIPs from the second wafer storage container105B are finished processing, the second embodiment apparatus300may then be used to unload the second wafer storage container105B from the load port107and to load the third wafer storage container105C onto the load port107via the process shown and described above with reference toFIGS.20A-29B.

As discussed above, the second embodiment positioning apparatus300according to the present disclosure may provide significant cost savings and efficiency improvements for an AMHS100. In particular, an AMHS100utilizing a second embodiment apparatus300to perform a process as shown inFIGS.20A-29B and31may provide increased efficiency in the loading of storage containers for processing by the processing apparatuses, which may also be referred to as “stocking.” The Delivery Time Accuracy-In (DTA-IN) in an AMHS100system such as shown and described above may be defined as the time between when the AMHS vehicle, such as an OHT vehicle103, picks up a storage container105containing WIPs intended for processing by a processing apparatus110, and when the wafer storage container105is actually delivered to the load port107associated with the processing apparatus110. In a conventional overhead AMHS100system such as shown and described with reference toFIG.1, the average DTA-IN may be on the order of ˜120 seconds. In comparison, an AMHS100utilizing the second embodiment positioning apparatus300and employing a process such as shown inFIGS.20A-29B and31may have an average DTA-IN that is about 15 seconds. In various embodiments, an AMHS100utilizing a second embodiment positioning apparatus300may have an average DTA-IN that is at least 60%, such as at least 75%, including more than 80% lower (e.g., 80-90% lower) than the average DTA-IN of a conventional AMHS. Furthermore, by utilizing a second embodiment positioning apparatus300and a process as shown inFIGS.20A-29B and31, the transfer efficiency of the AMHS100may improve by at least about 50%, including by at least 60%, relative to a conventional AMHS. This may provide significant cost savings, including up to ⅓ of the cost or more for an overhead AMHS.

In various embodiments, an AMHS100utilizing a second embodiment positioning apparatus300may use a process as shown inFIGS.12A-19B and30to improve shipping efficiency and may use a process as shown inFIGS.20A-29B and31to improve stocking efficiency. The AMHS100may switch between these processes at some or all of the loading ports107of the facility to provide higher prioritization for shipping and for stocking as appropriate.

FIG.30is a flowchart illustrating a method400of processing semiconductor wafers in accordance with some embodiments. Referring toFIGS.4A,4B,12A,12B and30, in step402of method400, a first wafer storage container105A may be removed from a load port107using a positioning apparatus200,300operatively coupled to the load port107. The first wafer storage container105A may include semiconductor wafers109that have been processed using a wafer processing apparatus110associated with the load port107. Referring toFIGS.5A,5B,13A,13B and30, in step404of method400, the first wafer storage container105A may be moved along a first direction with respect to the load port107(e.g., a horizontal direction parallel to the direction of arrow hd2inFIGS.5B and13B) using the positioning apparatus200,300to displace the first wafer storage container105A from the load port107. Referring toFIGS.6A,6B,14A,14B and30, a second wafer storage container105B may be transferred from a vehicle (e.g., an OHT vehicle103) of the AMHS100to the load port107along a second direction (e.g., a vertical direction) that is perpendicular to the first direction while the first work-in-progress109is displaced from the load port107. Referring toFIGS.7A,7B,8A,8B,17A,17B,18A-18B and30, in step406of method400, the first wafer storage container105A may be transferred from the positioning apparatus200,300to a vehicle103of the AMHS100along the second direction.

FIG.31is a flowchart illustrating a method500of processing semiconductor wafers in accordance with another embodiment. Referring toFIGS.20A,20B,21A,21B and31, in step502of method500, a second wafer storage container105B may be received on a support element301of a positioning apparatus300that is operatively coupled to a load port107having a first wafer storage container105A located on the load port107. The second wafer storage container105B may contain semiconductor wafers109for processing by a wafer processing apparatus110associated with the load port107. Referring toFIGS.22A,22B,23A,23B,24A,24B,26A,26B and31, in step504of method500, the second wafer storage container105B may be moved along a first direction with respect to the load port107(e.g., a horizontal direction parallel to the direction of arrow hd2inFIGS.26B) to position the second wafer storage container105B over a surface104of the load port107after the first wafer storage container105A is transferred from the load port107to a vehicle103of an automated material handling system100along a second direction (i.e., a vertical direction) that is perpendicular to the first direction. Referring toFIGS.27A,27B and31, in step506of method500, the support element301may be moved along the second direction (i.e., a vertical direction) to load the second wafer storage container105B onto the load port107.

Generally, the structures and methods of the present disclosure may be used to improve the efficiency of an automated material handling system100(AMHS), such as an overhead AMHS100used in a semiconductor manufacturing facility. An apparatus (200,300) according to various embodiments may be operatively coupled to a load port107of a processing apparatus110for processing works-in-progress (WIPs), which may include semiconductor wafers109contained in a wafer storage container105, such as a FOUP. The apparatus (200,300) may include a support element (203,301) that is configured to support a WIP, such as by supporting a wafer storage container105containing one or more WIPs, above a surface of the load port107, and is also moveable in two perpendicular directions (e.g., vertically and horizontally) with respect to the load port107. In one mode of operation, the apparatus (200,300) may be configured to cause the support element (203,301) to remove a first WIP from the load port107, and to move the support element (203,301) in a first (e.g., horizontal) direction to displace the first WIP from the load port107while a second WIP is loaded onto the load port in a second (e.g., vertical) direction by a vehicle103of the AMHS100. The first WIP may then be transferred from the support element (203,301) to a vehicle103of the AMHS100, which may be the same vehicle103that delivers the second group of WIPs. This may significantly reduce the time required to transfer processed WIPs to the AMHS100(e.g., DTA-OUT), and may also reduce the event count of the AMHS100, resulting in improved manufacturing efficiency and lower cost.

In another mode of operation, a vehicle103may transfer a WIP to be processed to the support element (203,301) of the apparatus (200,300). The support element (203,301) may function as a “buffer” by holding the WIP to be processed until the WIP that is currently being processed is transferred to a vehicle103of the AMHS100. Then, the apparatus (200,300) may transfer the WIP to be processed from the support element (203,301) to the load port107. This may significantly reduce the time to transfer WIPs to be processed to the load port107of the processing apparatus110(e.g., DTA-IN), and may also reduce event count of the AMHS100, resulting in improved manufacturing efficiency and lower cost.

Referring toFIGS.1-19B and30, a method of processing semiconductor wafers that may include removing a first wafer storage container105A from a load port107using a positioning apparatus (200,300) operatively coupled to the load port107, the first wafer storage container105A containing semiconductor wafers109processed by a wafer processing apparatus110associated with the load port107; moving the first wafer storage container105A, using the positioning apparatus (200,300), along a first direction with respect to the load port107to displace the first wafer storage container105A from the load port107and enable a second wafer storage container105B containing semiconductor wafers109for processing by the wafer processing apparatus110to be transferred from a vehicle103of an automated material handling system100onto the load port107along a second direction that is perpendicular to the first direction; and transferring the first wafer storage container from the positioning apparatus to a vehicle of the automated material handling system along the second direction.

In an embodiment, the vehicle103of the automated material handling system100that transfers the second wafer storage container105B to the load port107may be the same vehicle103to which the first wafer storage container105A is transferred from the positioning apparatus (200,300).

In another embodiment, the first direction is a vertical direction and the second direction is a horizontal direction.

In another embodiment, the first wafer storage container105A may be lifted from a surface104of the load port107by the positioning apparatus (200,300) to remove the first wafer storage container105A from the load port107.

In another embodiment, the method of processing semiconductor wafers may further include moving the first wafer storage container105A using the positioning apparatus (200,300) to position the first wafer storage container105A over an upper surface of the second wafer storage container105B on the load port107prior to transferring the first wafer storage container105A to the vehicle103of the automated material handling system100.

In another embodiment, the positioning apparatus (200,300) may include a support element (203,301) configured to engage a wafer storage container105and support the wafer storage container105above a surface of the load port107, and the method may further include moving the support element (203,301) of the positioning apparatus (200,300) to engage with the second wafer storage container105B located on the load port107after the first wafer storage container105A is transferred to the vehicle103of the automated material handling system100; and removing the second wafer storage container105B from the load port107using the positioning apparatus (200,300) when the semiconductor wafers of the second wafer storage container105B have been processed by the wafer processing apparatus110.

Referring toFIGS.20A-29B and31, an additional embodiment is drawn to a method of processing semiconductor wafers that includes receiving, on a support element301of a positioning apparatus300operatively coupled to a load port107associated with a wafer processing apparatus110, a second wafer storage container105B containing semiconductor wafers109for processing by the wafer processing apparatus110while a first wafer storage container105A may be located on the load port107; moving the support element301using the positioning apparatus300along a first direction with respect to the load port107to position the second wafer storage container105B over a surface104of the load port107after the first wafer storage container105A may be transferred from the load port107to a vehicle103of an automated material handling system100along a second direction that is perpendicular to the first direction; and moving the support element301using the positioning apparatus300along the second direction to load the second wafer storage container105B onto the surface of the load port107.

In an embodiment, the first direction is a vertical direction and the second direction is a horizontal direction.

In another embodiment, the method may further include moving the support element301using the positioning apparatus300in a horizontal direction to laterally displace the support element301from the surface104of the load port107and the second wafer storage container105B located on the surface104of the load port107, and moving the support element301using the positioning apparatus300into a position to receive a third wafer storage container105C containing semiconductor wafers109for processing by the wafer processing apparatus110while the semiconductor wafers109of the second wafer storage container105B are being processed by the wafer processing apparatus110.

In another embodiment, moving the support element301into a position to receive a third wafer storage container105C may include moving the support element301using the positioning apparatus300in a vertically upwards direction laterally adjacent to the second wafer storage container105B located on the load port107, and moving the support element301using the positioning apparatus300in a horizontal direction over an upper surface of the second wafer storage container105B located on the load port107.

In another embodiment, the method may further include receiving, on the support element301, a third wafer storage container105C containing semiconductor wafers109for processing by the wafer processing apparatus110from a vehicle103of the automated material handling system100, and moving the support element301using the positioning apparatus300in a horizontal direction to laterally displace the support element301and the third wafer storage container105C from the upper surface of the second wafer storage container105B.

Referring toFIGS.1-29B, an additional embodiment is drawn to a positioning apparatus (200,300) operatively coupled to a load port107that is configured to receive a wafer storage container105containing semiconductor wafers109for processing by a wafer processing apparatus110, such that the positioning apparatus (200,300) may include at least one vertical support member (201,307); a support element (203,301) coupled to the at least one vertical support member (201,307) and configured to support a wafer storage container105above a surface of the load port107; a vertical translation mechanism (208,303) coupled to the support element (203,301) that is configured to translate the support element (203,301) in a vertical direction with respect to the load port107; and a horizontal positioning mechanism (205,210,305) coupled to the support element (203,301) that is configured to move the support element (203,301) in a horizontal direction with respect to the load port107.

In an embodiment, the at least one vertical support member may include a pair of support rods201and the support element includes a pair of hooks203configured to lift the wafer storage container105from the load port107, and each hook203is coupled to a respective support rod201of the pair of support rods201.

In another embodiment, the pair of support rods201and the pair of hooks203may be pivotable with respect to the load port107, and the horizontal positioning mechanism (205,210) moves the pair of hooks203in a horizontal direction by pivoting the support rods201and the hooks203with respect to the load port107.

In another embodiment, the pair of hooks203may be configured to lift the wafer storage container105by engaging a pair of handles115of the wafer storage container105as the pair of hooks203are translated in a vertically upward direction by the vertical translation mechanism.

In another embodiment, each hook203of the pair of hooks203may be a retractable hook that retracts as the pair of hooks203are translated vertically downward below a height of a pair of handles115of the second storage container105B.

In another embodiment, the support element (301) may include a support tray301and the horizontal positioning mechanism305moves the support tray301in a horizontal direction relative to the at least one vertical support member307.

In another embodiment, the support tray301may include a flat portion309that supports a wafer storage container105, and an open region310interior of the flat portion309that enables the support tray301to lower the wafer storage container105onto the load port107.

In another embodiment, the flat portion309of the support tray301may be moveable in a horizontal direction between an upper surface of the load port107and a lower surface of a wafer storage container105that is loaded onto the load port107.

In another embodiment, the wafer storage container105is a front opening unified pod (FOUP).

The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.