Patent ID: 12237196

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.

A plurality of semiconductor wafers and/or other types of substrates may be transported throughout a semiconductor fabrication facility in a transport carrier. A transport carrier may include a wafer cassette, a front-opening unified pod (FOUP), a pod, a container, or a similar type of device. To transfer a semiconductor wafer from a transport carrier to a semiconductor processing tool, the transport carrier may be placed in and/or on a load port associated with the semiconductor processing tool. A transport tool included in an interface tool (e.g., an equipment front end module (EFEM) or similar type of interface tool) that is situated between the semiconductor processing tool and the load port may remove the semiconductor wafer from the transport carrier. The transport tool may transfer the semiconductor wafer from the transport carrier to the semiconductor processing tool through a chamber of the interface tool. The transport tool may perform the above-described process in reverse to transfer the semiconductor wafer from the semiconductor processing tool to the transport carrier after processing.

Semiconductor wafers may be exposed to contaminants (e.g., volatile organic compounds (VOCs), dust, debris, and other types of contaminants) in the semiconductor fabrication facility during transfer of the semiconductor wafers between a load port and an associated semiconductor processing tool. These contaminants may cause semiconductor device failures, may cause defects to occur in the integrated circuits and/or semiconductor devices formed in the semiconductor fabrication facility, and may reduce manufacturing yield and quality, among other examples. Moreover, the impact of the contaminants in the semiconductor fabrication facility may continue to become more significant due to decreased tolerance to the contaminants as device and/or feature sizes of the integrated circuits and/or semiconductor devices, that are to be formed on semiconductor wafers in the semiconductor fabrication facility, continue to shrink.

Some implementations described herein provide a multiple transport carrier docking device that can be positioned between a load port and an interface tool to reduce and/or minimize cross contamination of semiconductor wafers that are transferred between the load port and an associated semiconductor processing tool. The multiple transport carrier docking device may be capable of forming an air-tight seal around a transport carrier while the transport carrier is in a chamber of the multiple transport carrier docking device. In this way, semiconductor wafers in the transport carrier may be accessed by a transport tool while the air-tight seal around the transport carrier prevents and/or reduces the likelihood that contaminants in the semiconductor fabrication facility will reach the semiconductor wafers. Accordingly, the air-tight seal around the transport carrier may reduce defects of the semiconductor wafers that might otherwise be caused by the contaminants, may increase manufacturing yield and quality in the semiconductor fabrication facility, and/or may permit the continued reduction in device and/or feature sizes of integrated circuits and/or semiconductor devices that are to be formed on semiconductor wafers.

Moreover, the multiple transport carrier docking device is capable of storing and/or staging a plurality of transport carriers in the chamber at the same time. This may permit transport carriers to be cycled through more quickly as the associated semiconductor processing tool processes the semiconductor wafers included in the plurality of transport carriers, which may increase the capacity and throughput of the associated semiconductor processing tool.

FIG.1is a diagram of an example semiconductor processing environment100described herein. The example semiconductor processing environment100may include, or may be included in, a semiconductor fabrication facility, a semiconductor foundry, a semiconductor processing facility, a semiconductor clean room, and/or another environment in which semiconductor wafers and/or devices are processed. As shown inFIG.1, the example semiconductor processing environment100may include a semiconductor processing tool102, a load port104, an interface tool106, and a docking device108, among other tools and/or devices.

The semiconductor processing tool102may include one or more tools configured to perform one or more semiconductor processing operations on one or more semiconductor wafers and/or devices. For example, the semiconductor processing tool102may include a deposition tool (e.g., a semiconductor processing tool configured to deposit one or more layers onto a semiconductor wafer), a plating tool (e.g., an electroplating tool configured to deposit one or more metal layers onto a semiconductor wafer), an exposure tool (e.g., an extreme ultraviolet (EUV) tool, an electron beam (e-beam) tool), an etch tool (e.g., a wet etch tool, a dry etch tool), or another type of semiconductor processing tool.

The load port104may include a shuttle platform110configured to receive and support a transport carrier112. The load port104and the shuttle platform110may receive the transport carrier112from a transport robot, a transport cart, an overhead hoist transport (OHT), or another device configured to move transport carriers to and from various locations in the example semiconductor processing environment100.

The transport carrier112may include a wafer cassette, a FOUP, a pod, a container, or a similar type of device configured to hold and/or store a plurality of semiconductor wafers. The transport carrier112may include a body114configured to rest on the shuttle platform110. The body114may be further configured to store a plurality of semiconductor wafers, semiconductor devices, and/or substrates that are to be used in semiconductor processing. The transport carrier112may further include a carrier door116. The carrier door116may be attached to the body114and may form an air-tight seal (e.g., a hermetic seal) between the carrier door116and the body114to reduce, minimize, and/or prevent contamination of the semiconductor wafers stored in the body114.

The interface tool106may include an EFEM or another tool that includes a chamber118. Air may be provided to the chamber118through a filter120(e.g., a high-efficiency particulate air (HEPA) filter or another type of air filter) configured to filter or remove particles and other contaminants from the incoming air. The chamber118may further be vented through an exhaust122.

The interface tool106may further include a wafer transport tool124in the chamber118. The wafer transport tool124may include a robotic arm or another type of tool that is configured to transport semiconductor wafers between a transport carrier112and the semiconductor processing tool102. The wafer transport tool124may receive and/or obtain a semiconductor wafer from a transport carrier112through an opening126between the docking device108and the interface tool106, and may provide the semiconductor wafer to the semiconductor processing tool102through an opening128between the interface tool106and the semiconductor processing tool102. Moreover, the wafer transport tool124may receive and/or obtain a semiconductor wafer from a semiconductor processing tool102through the opening128, and may provide the semiconductor wafer to a transport carrier112through the opening126. In some implementations, the wafer transport tool124transfers semiconductor wafers between a transport carrier112and a staging area of the semiconductor processing tool102. In some implementations, the wafer transport tool124transfers semiconductor wafers between a transport carrier112and a processing chamber of the semiconductor processing tool102.

The docking device108is a device that is configured to permit the transfer of semiconductor wafers between a transport carrier112and the semiconductor processing tool102in a manner that reduces the likelihood of exposure of semiconductor wafers to contaminants that may be present in the example semiconductor processing environment100. The docking device108may be referred to as a multiple transport carrier docking device in that the docking device108is configured to (and/or capable of) storing and/or staging a plurality of transport carriers112in a first chamber130, as shown inFIG.1. The wafer transport tool124may access a transport carrier112(e.g., the body114of the transport carrier112) through the opening126and through a second chamber132of the docking device108.

The first chamber130and the second chamber132may be separated by a divider wall134. The divider wall134may include a rigid or semi-rigid structure that extends from the top of the first chamber130and the second chamber132, to the bottom of the first chamber130and the second chamber132. The divider wall134may further extend from one side of the first chamber130and the second chamber132to another (opposing) side of the first chamber130and the second chamber132.

An opening136may be provided through the divider wall134, which may be sealed by a chamber door138. In particular, the chamber door138may be pressed against the divider wall134to form an air-tight seal (e.g., a hermetic seal) between the divider wall134and the chamber door138. The air-tight seal between the divider wall134and the chamber door138functions as an air-tight seal between the first chamber130and the second chamber132. The divider wall134and the chamber door138may form the air-tight seal when the chamber door138is in a closed position, as shown inFIG.1. The air-tight seal may reduce, minimize, and/or eliminate the likelihood that contaminants in the example semiconductor processing environment100might otherwise travel from the first chamber130to the second chamber132through the opening136in the divider wall134.

In some implementations, the divider wall134and/or the chamber door138may include a gasket, a strip, or another component to form the air-tight seal. The gasket of the divider wall134, if included, may be formed around the opening136in the divider wall134. The gasket of the chamber door138, if included, may be formed in a shape that substantially fits around the opening136in the divider wall134. The gasket of the divider wall134and/or the gasket of the chamber door138may be formed of a soft material and/or of a deformable material to permit the air-tight seal to be formed. For example, the gasket of the divider wall134and/or the gasket of the chamber door138may be formed of a plastic material, a rubber material, a silicone material, or a similar material. In some implementations, the material of the gasket of the divider wall134and/or the gasket of the chamber door138includes a gas impermeable material.

The first chamber130of docking device108may include a door140that seals around an opening at a first side (e.g., a first side wall) of the docking device108. In some implementations, the door140(and the associated opening) is on an opposing side of the docking device108to the opening126, which may be at a second side (e.g., a second side wall) of the docking device108. In some implementations, the door140(and the associated opening) and the opening126are on adjacent sides (e.g., adjacent side walls) of the docking device108.

The door140(and the associated opening) may be orientated toward the load port104to permit transport carriers112to be transferred between the shuttle platform110and the first chamber130. The door140may be opened (e.g., removed from the opening) to provide access to the first chamber130for insertion of a transport carrier112into the first chamber130, and for removal of a transport carrier112from the first chamber130. The opening126may provide access to the second chamber132for the wafer transport tool124.

Air may be provided to the first chamber130through a filter142(e.g., a HEPA filter or another type of air filter) configured to filter or remove particles and other contaminants from the incoming air flowing into the first chamber130. The first chamber130may further be vented through an exhaust144.

As indicated above, the docking device108may be configured to store and/or stage a plurality of transport carriers112in the first chamber130. The first chamber130may include a plurality of moveable platforms146on which transport carriers112may be placed and/or supported. Each moveable platform146may be configured support a respective transport carrier112. Each movable platform146may be sized to a greater size relative to the transport carriers112(e.g., a greater length and/or a greater width) to reduce, minimize, and/or prevent vibration of the transport carriers. The movable platforms146may be configured to slide and/or otherwise move in one or more directions within the first chamber130to permit access to each moveable platform146through the opening that is orientated toward the load port104. For example, the moveable platforms146may be configured to slide and/or otherwise move in a vertical direction (e.g., up and down) in the first chamber130. As another example, the moveable platforms146may be configured to slide and/or otherwise move in a horizontal direction (e.g., side to side) in the first chamber130. As another example, the moveable platforms146may be configured to slide and/or otherwise move in a vertical direction (e.g., up and down) and in a horizontal direction (e.g., side to side) in the first chamber130. In these examples, all of the moveable platforms146may move together at the same time, or individual moveable platforms146may move independently of the other moveable platforms146.

The docking device108may include a plurality of shuttle trays148. Each moveable platform146may include a respective shuttle tray148and one or more latches150. Each shuttle tray148may be configured to receive and support a respective transport carrier112. Moreover, each shuttle tray148may slide or otherwise move in one or more directions to move a transport carrier112toward and away from a sealing component152in the first chamber130. For example, a shuttle tray148may slide and/or otherwise move relative to an associated moveable platform146to extend toward the sealing component152, and may slide and/or otherwise move relative to the associated moveable platform146to retract away from the sealing component152.

The one or more latches150included in a moveable platform146may be attached, connected, and/or otherwise supported by the moveable platform146. The one or more latches150may be configured to extend away from the moveable platform146and toward a moveable frame154to which the sealing component152is attached, mounted, and/or otherwise supported. Moreover, the one or more latches150may be configured to retract toward the moveable platform146and away from the moveable frame154. The one or more latches150may connect to the moveable platform146when the one or more latches150are extended. This permits movement of the moveable platform146to cause the moveable frame154to move along with the moveable platform146. In this way, the moveable frame154may be an unpowered moveable frame (e.g., a moveable frame without a dedicated motor and/or drive mechanism to move the moveable frame), which reduces the complexity of the moveable frame154. Moreover, the one or more latches150permit the movement of the moveable platform146and the movement of the moveable frame154to be synchronized.

The sealing component152included in the first chamber130of the docking device108may be configured to reduce, minimize, and/or eliminate the likelihood of exposure to contaminants that may be present in the example semiconductor processing environment100when a semiconductor wafer is transferred between the transport carrier112and the semiconductor processing tool102. The sealing component152may be pressed against the moveable frame154on a side (or face) of the moveable frame154facing the first chamber130. One or more gaskets may be located between the sealing component152and moveable frame154to reduce, minimize, and/or prevent air (and contaminants carried by the air) from passing between the sealing component152and the moveable frame154.

The sealing component152may include one or more portions that are configured to form an air-tight seal (e.g., a hermetic seal) around a transport carrier112when a transport carrier112is extended toward the sealing component152on a shuttle tray148. For example, the shuttle tray148may slide or otherwise move the transport carrier112toward the sealing component152in the first chamber130. With the transport carrier112extended toward the sealing component152, the sealing component152may contract around the transport carrier112(e.g., around the body114of the transport carrier112) to form the air-tight seal between the sealing component152and the transport carrier112.

The one or more portions of the sealing component152may be positioned around an opening in the moveable frame154. The carrier door116of the transport carrier112may extend into and/or through the opening in the moveable frame154when the transport carrier112extended toward the sealing component152. This permits the one or more portions of the sealing component152to contract around the body114of the transport carrier112(e.g., to form the air-tight seal around the body114of the transport carrier112) as opposed to the carrier door116of the transport carrier112, which permits the carrier door116to be removed from the body114of the transport carrier112.

In some implementations, the sealing component152(or the portions thereof) are formed of a relatively soft material (e.g., softer than the material of the body114of the transport carrier112) to permit the air-tight seal to be formed around the transport carrier112. For example, the sealing component152(or the portions thereof) may be formed of a plastic material, a rubber material, a silicone material, a gas impermeable, or a similar material. In some implementations, the sealing component152(or the portions thereof) includes a gasket, a strip, or a similar component formed of a relatively soft material that is pressed against the body114of the transport carrier112to form the air-tight seal.

When the air-tight seal is formed between the sealing component152and a transport carrier112, the chamber door138may remove the carrier door116from the body114of the transport carrier112. After removing the carrier door116, the chamber door138may transition from the closed position shown inFIG.1to an open position, which releases the air-tight seal between divider wall134and the chamber door138. Here, the chamber door138(with the removed carrier door116) may move backwards away from the divider wall134toward the opening126, and may move downward into the second chamber132(e.g., after moving backwards away from the divider wall134). In this way, the opening136in the divider wall134is cleared such that the wafer transport tool124is permitted to access the transport carrier112(e.g., the body114of the transport carrier112) through the opening136in the divider wall134and the opening126while the air-tight seal is formed around the transport carrier112by the sealing component152.

Prior to removing the carrier door116from the body114of the transport carrier112, the moveable platform146on which the transport carrier112may move to adjust the position of the transport carrier112. In this way, the moveable platform146may move to align the carrier door116, the opening in the moveable frame154, and the opening136in the divider wall134so that the carrier door116is accessible by the chamber door138, and so that the carrier door116may pass through the opening in the moveable frame154and the opening136in the divider wall134.

The moveable frame154may be permitted to slide and/or otherwise move along a set of tracks156. The track(s)156may be mounted, connected, attached, and/or supported by the divider wall134. The track(s)156may include one or more tracks, one or more rails, one or more tubes, roller bearings, or there types of structures that permit the moveable frame154to slide and/or otherwise move based on movement of a moveable platform146. The track(s)156may include one or more elongated members that extend parallel to the direction of travel of the moveable frame154. The length of the elongated members may be greater than the length of the moveable frame154to permit the moveable frame to move along the track(s)156.

In some implementations, the docking device108includes one or more sensors (e.g., proximity sensors, hall effect sensors, or other types of sensors) configured to detect and/or indicate whether the carrier door116, the opening in the moveable frame154, and the opening136are aligned. In some implementations, the one or more sensors cause an indication (e.g., a visual indication, an audible indication, or another type of indication) to be presented to an operator if the moveable platform146is manually operated by the operator. In some implementations, the one or more sensors automatically cause the movement of the moveable platform146to stop based on detecting or determining that alignment between the carrier door116, the opening in the moveable frame154, and the opening136. In some implementations, the one or more sensors automatically provide a signal, a message, or another type of indicator to a processor or controller of the docking device108based on detecting or determining that alignment between the carrier door116, the opening in the moveable frame154, and the opening136, and the processor or controller automatically causes the movement of the moveable platform146to stop based on the indicator.

The wafer transport tool124may transfer semiconductor wafers between the transport carrier112and the semiconductor processing tool102after the air-tight seal is formed around the transport carrier112by the sealing component152, and after the chamber door138is opened. For example, the wafer transport tool124may obtain and/or retrieve a semiconductor wafer from the transport carrier112through the opening136in the divider wall134and through the opening126, and may provide the semiconductor wafer to the semiconductor processing tool102through the opening128. As another example, the wafer transport tool124may obtain a semiconductor wafer from the semiconductor processing tool102through the opening128, and may provide the semiconductor wafer to the transport carrier112through the opening126and the opening136in the divider wall134.

In this way, with the carrier door116removed and the chamber door138in the open position, air-tight seals are formed between the body114of the transport carrier112and the side wall on which the opening126is located. In particular, an air-tight seal may be formed between the body114of the transport carrier112and the sealing component152, an air-tight seal may be formed between the sealing component152and the moveable frame154, an air-tight seal may be formed between the moveable frame and a side of the divider wall134, an air-tight seal may be formed between the divider wall134and the top, bottom, and sides of the first chamber130and the second chamber132. This provides an air-tight seal from the transport carrier112through the second chamber132and to the opening128. The air-tight seal from the transport carrier112through the second chamber132and to the opening128permits the transport carrier112to be accessed without exposing the semiconductor wafers that are between the transport carrier112and the semiconductor processing tool102to contaminants in the example semiconductor processing environment100.

As indicated above,FIG.1is provided as an example. Other examples may differ from what is described with regard toFIG.1.

FIGS.2A-2Fare diagrams of example implementations of the sealing component152for forming an air-tight seal around a transport carrier112described herein.FIG.2Aillustrates perspective views of example implementations210and220of the sealing component152in which the sealing component152includes four portions: a portion152a, a portion152b, a portion152c, and a portion152d. Example implementation210illustrates an example of the sealing component152in an expanded configuration, where the portion152a, the portion152b, the portion152c, and the portion152dare not contracted around the body114of the transport carrier112. In this configuration, the portion152a, the portion152b, the portion152c, and the portion152dmay spaced away from the body114of the transport carrier112at a distance that permits the door140and the body114of the transport carrier112to fit through an opening212formed by the portion152a, the portion152b, the portion152c, and the portion152d. The opening212may be referred to as an airflow/vacuum hole.

As further shown in the example implementation220inFIG.2A, the sealing component152may transition to a contracted configuration, in which the portion152a, the portion152b, the portion152c, and the portion152dare contracted around the body114of the transport carrier112to form the air-tight seal around the transport carrier112.

FIG.2Billustrates an elevation view of an example implementation230, which shows a first position240of the portion152a, the portion152b, the portion152c, and the portion152d, and a second position250of the portion152a, the portion152b, the portion152c, and the portion152d. The first position240may correspond to the expanded configuration illustrated in the example implementation210ofFIG.2A, and the second position250may correspond to the contracted configuration illustrated in the example implementation220ofFIG.2A.

As shown inFIG.2B, in some implementations, the portion152a, the portion152b, the portion152c, and the portion152dmay each transition between the first position240and the second position250. For example, the portion152amay move downward from the first position240to the second position250, and may move upward from the second position250to the first position240. As another example, the portion152bmay move upward from the first position240to the second position250, and may move downward from the second position250to the first position240. As another example, the portion152cand the portion152dmay each move inward from the first position240to the second position250, and may each move outward from the second position250to the first position240. In some implementations, one or more of the portion152a, the portion152b, the portion152c, or the portion152dtransition between the first position240and the second position250in a non-linear path of travel. In some implementations, one or more of the portion152a, the portion152b, the portion152c, or the portion152dtransition between the first position240and the second position250in a non-linear path of travel.

As further shown inFIG.2B, in the example implementation230, the portion152amay cover a first portion of the top of the transport carrier112, a first portion of a first side of the transport carrier112, and a first portion of a second side of the transport carrier112opposing the first side. The portion152bmay cover a first portion of the bottom of the transport carrier112, a second portion of the first side of the transport carrier112, and a second portion of the second side of the transport carrier112. The portion152cmay cover a second portion of the top of the transport carrier112, a third portion of a first side of the transport carrier112, and a second portion of the bottom of the transport carrier112. The portion152dmay cover a third portion of the top of the transport carrier112, a third portion of a first side of the transport carrier112, and a third portion of the bottom of the transport carrier112.

The first portion of the top covered by the portion152a, the second portion of the top covered by the portion152c, and the third portion of the top covered by the portion152dmay substantially encompass the entire top of the transport carrier112. The first portion of the bottom covered by the portion152b, the second portion of the bottom covered by the portion152c, and the third portion of the top covered by the portion152dmay substantially encompass the entire bottom of the transport carrier112. The first portion of the first side covered by the portion152a, the second portion of the first side covered by the portion152b, and the third portion of the first side covered by the portion152cmay substantially encompass the entire first side of the transport carrier112. The first portion of the second side covered by the portion152a, the second portion of the second side covered by the portion152b, and the third portion of the second covered by the portion152dmay substantially encompass the entire second side of the transport carrier112. Other example implementations of the sealing component152having four portions may be used with the docking device108.

FIG.2Cillustrates an elevation view of an example implementation260. In the example implementation260, the sealing component152includes a plurality of portions: a portion152aand a second portion152b. The portion152amay cover substantially the entire top of the transport carrier112, a first portion of a first side of the transport carrier112, and a first portion of a second side of the transport carrier112opposing the first side. The portion152bmay cover substantially the entire bottom of the transport carrier112, a second portion of the first side of the transport carrier112, and a second portion of the second side of the transport carrier112. The first portion of the first side covered by the portion152a, and the second portion of the first side covered by the portion152bmay substantially encompass the entire first side of the transport carrier112. The first portion of the second side covered by the portion152a, and the second portion of the second side covered by the portion152bmay substantially encompass the entire second side of the transport carrier112.

FIG.2Dillustrates an elevation view of an example implementation270. In the example implementation270, the sealing component152includes a plurality of portions: a portion152aand a second portion152b. The portion152amay cover substantially an entire first side of the transport carrier112, a first portion of the top of the transport carrier112, and a first portion of the bottom of the transport carrier112. The portion152bmay cover substantially an entire second side of the transport carrier112opposing the first side, a second portion of the top of the transport carrier112, and a second portion of the bottom of the transport carrier112. The first portion of the top covered by the portion152a, and the second portion of the top covered by the portion152bmay substantially encompass the entire top of the transport carrier112. The first portion of the bottom covered by the portion152a, and the second portion of the bottom covered by the portion152bmay substantially encompass the entire bottom of the transport carrier112.

FIG.2Eillustrates an elevation view of an example implementation280. In the example implementation280, the sealing component152includes a plurality of portions: a portion152aand a portion152b. As shown inFIG.2E, in the example implementation280, the portion152amay cover substantially the entire top of the transport carrier112and substantially an entire first side of the transport carrier112. The portion152bmay cover substantially the entire bottom of the transport carrier112and substantially an entire second side of the transport carrier112opposing the first side. Other example implementations of the sealing component152having four portions may be used with the docking device108.

FIG.2Fillustrates an elevation view of an example implementation290. In the example implementation290, the sealing component152includes a plurality of portions: a portion152a, a portion152b, and a portion152c. The portion152amay cover a first portion of the top of the transport carrier112and substantially an entire first side of the transport carrier112. The portion152bmay cover a second portion of the top side of the transport carrier112and substantially an entire second side of the transport carrier112opposing the first side. The portion152cmay cover the entire bottom of the transport carrier112. Other example implementations of the sealing component152having three portions may be used with the docking device108.

As indicated above,FIGS.2A-2Fare provided as examples. Other examples may differ from what is described with regard toFIGS.2A-2F. In some implementations, the sealing component152may include five or more portions in various configurations different from those described herein.

FIG.3is a diagram of portion300of the example semiconductor processing environment100ofFIG.1, described herein. As shown inFIG.3, the portion300may include the divider wall134, the chamber door138, a moveable platform146, a shuttle tray148, one or more latches150, the sealing component152, the moveable frame154, and the track(s)156.

The divider wall134may include an elongated body in which the opening136is included. The track(s)156may be attached, connected, and/or otherwise mounted to a side of the elongated body of the divider wall134. The moveable frame154may be mounted to and/or interfaced with the track(s)156. The moveable frame154may include a substantially planar body that permits the moveable frame154to move along the track(s)156substantially parallel to the elongated body of the divider wall134.

The sealing component152may include a plurality of portions, such as portion152a, portion152b, portion152c, and portion152d. The sealing component152(or the portions thereof) may be attached, connected, and/or otherwise mounted to a side of the elongated body of the moveable frame154, such as the side of the elongated body of the moveable frame154opposing the side of the elongated body of the moveable frame154that is orientated and/or facing toward the divider wall134. The sealing component152may be attached, connected, and/or otherwise mounted to the moveable frame154in a manner that permits the portions of the sealing component152to expand and contract between a first position240and a second position250to form or release an air-seal around a transport carrier112.

The body114of the transport carrier112may be positioned on the shuttle tray148above the moveable platform146. The one or more latches150of the moveable platform146may extend away from the moveable platform146and toward the moveable frame154. The one or more latches150include one or more tabs, hooks, pins, or other structures that connect with one or more connectors302included on the moveable frame154. With the one or more latches150connected with the one or more connectors302, movement of the moveable platform146may cause the moveable frame154to move along the track(s)156.

As further shown inFIG.3, the portion300may include the chamber door138. The chamber door138may include an elongated body that is substantially parallel to the elongated body of the divider wall134. Moreover, the chamber door138may include a mounting plate304attached, connected, and/or otherwise mounted to a support structure306. The support structure306may be attached, connected, and/or otherwise mounted to the elongated body of the chamber door138. The mounting plate304and the support structure306may be attached, connected, and/or otherwise mounted to a side of the elongated body of the chamber door138that faces the divider wall134. In this way, the mounting plate304faces the opening136in the divider wall134. In particular, the mounting plate and the support structure306may be mounted to the side of the chamber door138that faces the side of the divider wall134that opposes the side of the divider wall134on which the track(s)156, the moveable frame154, and the sealing component152are mounted.

The mounting plate304may be configured to remove a carrier door116from the body114of the transport carrier112. The mounting plate304may be configured to hold and/or support the carrier door116when the chamber door138moves between the closed position and the open position. The mounting plate304may be configured to place the carrier door116onto the body114of the transport carrier112. The mounting plate304may include one or more vacuum holes308and one or more latch keys310. The vacuum holes308may be connected to tube(s), plumbing fixture(s), and/or one or more other components that are configured to pull air through the vacuum holes308to form a negative pressure on the face of the mounting plate304near the vacuum holes308. The negative pressure may form a suction or a vacuum seal between the mounting plate304and the carrier door116. The mounting plate304may hold and/or support the carrier door116based on the negative pressure generated through the vacuum holes308.

The latch key(s)310may be configured to unlatch the carrier door116from the body114of the transport carrier112. For example, the latch key(s)310may include a key, an elongated member, or another component that is configured to open a door latch and/or a door lock on the carrier door116. In some implementations, the mounting plate304includes a single latch key310(e.g., on a side of the mounting plate304or substantially near a center of the mounting plate304). In some implementations, the mounting plate304includes a plurality of latch keys310substantially near one or more edges of the mounting plate304.

The support structure306may include a jack (e.g., a scissor jack, a hydraulic jack, a pneumatic jack, or another type of jack), a screw mechanism, a rail system, or another type of structure configured to extend the mounting plate304away from the elongated body of the chamber door138and contract the mounting plate304toward the elongated body of the chamber door138. In this way, the support structure306may extend the mounting plate304toward and/or through the opening136in the divider wall134to remove the carrier door116from the transport carrier112, may contract the mounting plate304after removing the carrier door116so that the chamber door138may be moved to the opened position, and may extend the mounting plate304toward transport carrier112to place the carrier door116onto the transport carrier112.

As indicated above,FIG.3is provided as an example. Other examples may differ from what is described with regard toFIG.3.

FIGS.4A-4Kare diagrams of one or more example implementations400described herein. The example implementation(s)400may include one or more example implementations illustrating various operations of the docking device108and other tools included in the example semiconductor processing environment100. As shown inFIG.4A, a transport carrier112may be placed on the shuttle platform110of the load port104. For example, a mobile robot, an OHT, or another transport tool may place the transport carrier112on the shuttle platform110.

As shown inFIG.4B, the door140on the side of the first chamber130may be opened to provide access to the docking device108through an opening402in the first chamber130. As further shown inFIG.4B, the moveable platforms146may move (e.g., downward in the first chamber130) to align an empty moveable platform146with the opening402in preparation for the transport carrier112on the shuttle platform110to be placed on the empty moveable platform146.

As shown inFIG.4C, the shuttle platform110may slide or otherwise move toward the opening402in the first chamber130such that the transport carrier112is fully inserted into the first chamber130through the opening402and placed on the empty moveable platform146. In particular, the transport carrier112may be placed on the shuttle tray148of the empty moveable platform146. In some implementations, the door140may be moved to close the opening402after the transport carrier112is placed on the empty moveable platform146. In some implementations, the door140may remain in place such that the opening402remains cleared after the transport carrier112is placed on the empty moveable platform146.

As shown inFIG.4D, the moveable platforms146may move (e.g., upward in the first chamber130) to align the transport carrier112with the sealing component152and/or the opening in the moveable frame154in preparation for the transport carrier112to be accessed by the wafer transport tool124.

As shown inFIG.4E, with the transport carrier112aligned with the sealing component152and/or the opening in the moveable frame154, the shuttle tray148may slide or otherwise extend toward the sealing component152such that the carrier door116is placed at least partially through the opening in the moveable frame154, and such that portions of the sealing component152are around the body114of the transport carrier112.

Moreover, the one or more latches150, of the moveable platform146on which the transport carrier112is positioned, may extend away from the moveable platform146and toward the moveable frame154. The one or more latches150may connect with one or more connectors302of the moveable frame154to permit the movement of the moveable platform146to cause the moveable frame154to move in synchronization with the moveable platform146.

With the portions of the sealing component152around a portion of the body114, the sealing component152may contract around the transport carrier112to form an air-tight seal around the body114of the transport carrier112. In particular, the air-tight seal may be formed between the sealing component152and the transport carrier112. In this way, the area around the transport carrier112is sealed to reduce, minimize, and/or eliminate the flow of contaminants from the example semiconductor processing environment100through the opening in the moveable frame154and the opening136in the divider wall134, and into the second chamber132. The portions of the sealing component152may transition from a first position240(e.g., corresponding to an expanded configuration) to a second position250(e.g., corresponding to a contracted configuration) to form the air-tight seal around the body114of the transport carrier112.

As shown inFIG.4F, with the air-tight seal formed around the transport carrier112by the sealing component152, the chamber door138may remove the carrier door116from the transport carrier112. For example, the support structure306may extend the mounting plate304toward the carrier door116through the opening136in the divider wall134. The one or more latch keys310on the mounting plate304may unlatch the carrier door116from the body114of the transport carrier112. The vacuum holes308on the mounting plate304may form a vacuum seal between the carrier door116and the mounting plate304. With the vacuum seal formed, the support structure306may contract the mounting plate304(with the carrier door116supported and/or held thereon) toward the chamber door138.

As further shown inFIG.4F, the chamber door138may slide and/or otherwise move backward away from the divider wall134and toward the opening126, which removes the air-tight seal between divider wall134and the chamber door138. In particular, the chamber door138may slide and/or otherwise move backward away from the divider wall134and toward the opening126after removing the carrier door116from the transport carrier112and contracting the mounting plate304toward the chamber door138. The chamber door138may slide and/or otherwise move backward away from the divider wall134a sufficient distance to permit the carrier door116to clear the divider wall134when the chamber door138slides and/or otherwise moves downward into the second chamber132.

As shown inFIG.4G, the chamber door138may slide and/or otherwise move out of the way of the opening136in the divider wall134such that the wafer transport tool124is permitted to access the transport carrier112through the opening136in the divider wall134. In some implementations, the chamber door138slides and/or otherwise moves downward within the second chamber132. In some implementations, the chamber door138slides and/or otherwise moves upward within the second chamber132. In some implementations, the chamber door138slides and/or otherwise moves to a side within the second chamber132. In some implementations, the chamber door138slides and/or otherwise moves in a combination of directions within the second chamber132.

As shown inFIG.4H, the wafer transport tool124of the interface tool106may retrieve and/or obtain a wafer404from the transport carrier112through the opening136in the divider wall134and through the opening126. In this way, the wafer transport tool124retrieves and/or obtains the wafer404from the transport carrier112while the air-tight seal is formed around the transport carrier112by the sealing component152. As shown inFIG.4I, the wafer transport tool124may retract the wafer404through the opening136in the divider wall134and through the opening126into the chamber118of the interface tool106. As shown inFIG.4J, the wafer transport tool124may provide the wafer404to the semiconductor processing tool102through the opening128. The wafer404may be processed by the semiconductor processing tool102through one or more semiconductor processing operations. The operations described above may be performed in a reverse order to place the wafer404back into the transport carrier112.

As shown inFIG.4K, the moveable platforms146may move in the first chamber130while the carrier door116of the transport carrier112is removed. This may permit other transport carriers112to be removed from the first chamber130and/or to permit other transport carriers112to be added to the first chamber130while semiconductor wafers of the transport carrier112are being processed by the semiconductor processing tool102. This may further increase the efficiency and throughput of the semiconductor processing tool102and/or the efficiency and throughput of the docking device108, as the docking device108may continue to be loaded and unloaded without stopping the productivity of the semiconductor processing tool102.

As indicated above,FIGS.4A-4Kare provided as examples. Other examples may differ from what is described with regard toFIGS.4A-4K.

FIG.5is a diagram of example components of a device500. In some implementations, one or more devices and/or tools of the example semiconductor processing environment100(e.g., the semiconductor processing tool102, the load port104, the interface tool106, and/or the multiple transport carrier docking device108) may include one or more devices500and/or one or more components of device500. As shown inFIG.5, device500may include a bus510, a processor520, a memory530, a storage component540, an input component550, an output component560, and a communication component570.

Bus510includes a component that enables wired and/or wireless communication among the components of device500. Processor520includes a central processing unit, a graphics processing unit, a microprocessor, a controller, a microcontroller, a digital signal processor, a field-programmable gate array, an application-specific integrated circuit, and/or another type of processing component. Processor520is implemented in hardware, firmware, or a combination of hardware and software. In some implementations, processor520includes one or more processors capable of being programmed to perform a function. Memory530includes a random access memory, a read only memory, and/or another type of memory (e.g., a flash memory, a magnetic memory, and/or an optical memory).

Storage component540stores information and/or software related to the operation of device500. For example, storage component540may include a hard disk drive, a magnetic disk drive, an optical disk drive, a solid state disk drive, a compact disc, a digital versatile disc, and/or another type of non-transitory computer-readable medium. Input component550enables device500to receive input, such as user input and/or sensed inputs. For example, input component550may include a touch screen, a keyboard, a keypad, a mouse, a button, a microphone, a switch, a sensor, a global positioning system component, an accelerometer, a gyroscope, and/or an actuator. Output component560enables device500to provide output, such as via a display, a speaker, and/or one or more light-emitting diodes. Communication component570enables device500to communicate with other devices, such as via a wired connection and/or a wireless connection. For example, communication component570may include a receiver, a transmitter, a transceiver, a modem, a network interface card, and/or an antenna.

Device500may perform one or more processes described herein. For example, a non-transitory computer-readable medium (e.g., memory530and/or storage component540) may store a set of instructions (e.g., one or more instructions, code, software code, and/or program code) for execution by processor520. Processor520may execute the set of instructions to perform one or more processes described herein. In some implementations, execution of the set of instructions, by one or more processors520, causes the one or more processors520and/or the device500to perform one or more processes described herein. In some implementations, hardwired circuitry may be used instead of or in combination with the instructions to perform one or more processes described herein. Thus, implementations described herein are not limited to any specific combination of hardware circuitry and software.

The number and arrangement of components shown inFIG.5are provided as an example. Device500may include additional components, fewer components, different components, or differently arranged components than those shown inFIG.5. Additionally, or alternatively, a set of components (e.g., one or more components) of device500may perform one or more functions described as being performed by another set of components of device500.

FIG.6is a flowchart of an example process600associated with accessing a transport carrier. In some implementations, one or more process blocks ofFIG.6may be performed by a multiple transport carrier docking device (e.g., the multiple transport carrier docking device108). In some implementations, one or more process blocks ofFIG.6may be performed by another device or a group of devices separate from or including the multiple transport carrier docking device, such as a semiconductor processing tool102, a load port104, an interface tool106, and/or another device. Additionally, or alternatively, one or more process blocks ofFIG.6may be performed by one or more components of device500, such as processor520, memory530, storage component540, input component550, output component560, and/or communication component570.

As shown inFIG.6, process600may include positioning a transport carrier on a moveable platform of a plurality of moveable platforms included in a first chamber of a multiple transport carrier docking device (block610). For example, the load port104(e.g., using the shuttle platform110) may position the transport carrier112on a moveable platform146of a plurality of moveable platforms146included in the first chamber130of the multiple transport carrier docking device108, as described above.

As further shown inFIG.6, process600may include contracting a sealing component of the multiple transport carrier docking device around the transport carrier to form an air-tight seal around the transport carrier (block620). For example, the multiple transport carrier docking device108may contract the sealing component152of the multiple transport carrier docking device108around the transport carrier112to form an air-tight seal around the transport carrier112, as described above.

As further shown inFIG.6, process600may include, after forming the air-tight seal around the transport carrier, removing a carrier door of the transport carrier and opening a chamber door of the multiple transport carrier docking device to permit access to the transport carrier through an opening in a divider wall between the first chamber and a second chamber of the multiple transport carrier docking device (block630). For example, the multiple transport carrier docking device108may, after forming the air-tight seal around the transport carrier112, remove the carrier door116of the transport carrier112and may open the chamber door138of the multiple transport carrier docking device108to permit access to the transport carrier112through the opening136in the divider wall134between the first chamber130and the second chamber132of the multiple transport carrier docking device108, as described above.

As further shown inFIG.6, process600may include accessing, using a wafer transport tool with the multiple transport carrier docking device, the transport carrier while the air-tight seal is around the transport carrier (block640). For example, the interface tool106may access, using the wafer transport tool124associated with the multiple transport carrier docking device108, the transport carrier112while the air-tight seal is around the transport carrier112, as described above.

Process600may include additional implementations, such as any single implementation or any combination of implementations described below and/or in connection with one or more other processes described elsewhere herein.

In a first implementation, accessing the transport carrier112includes retrieving a wafer404from the transport carrier112through the opening136and through the second chamber132while the air-tight seal is around the transport carrier112, and providing the wafer404to a semiconductor processing tool102. In a second implementation, alone or in combination with the first implementation, process600includes sliding, using a shuttle tray148on the moveable platform,146the transport carrier112toward the sealing component152, and contracting the sealing component152around the transport carrier112to form the air-tight seal around the transport carrier112includes contracting the sealing component152around the transport carrier112to form the air-tight seal around the transport carrier112after sliding the transport carrier toward112the sealing component152.

In a third implementation, alone or in combination with one or more of the first and second implementations, process600includes extending a latch150of the moveable platform146toward a moveable frame154to which the sealing component152is mounted, and inserting the latch150into a connector302on the moveable frame154, and moving the moveable platform146while the latch150is inserted into the connector302. In a fourth implementation, alone or in combination with one or more of the first through third implementations, moving the moveable platform146while the latch150is inserted into the connector302causes the moveable frame154to move along with the moveable platform146.

In a fifth implementation, alone or in combination with one or more of the first through fourth implementations, moving the moveable platform146while the latch150is inserted into the connector302includes moving the moveable platform146while the latch150is inserted into the connector302to orientate the transport carrier112in front of the opening136in the divider wall134. In a sixth implementation, alone or in combination with one or more of the first through fifth implementations, removing the carrier door116of the transport carrier112includes pressing a mounting plate304, attached to the chamber door138, against the carrier door116, unlatching, using a latch key310included on the mounting plate304, the carrier door116from a body114of the transport carrier112, forming a vacuum seal between the mounting plate304and the carrier door116, and retracting the mounting plate304toward the chamber door138while the vacuum seal is between the mounting plate304and the carrier door116.

AlthoughFIG.6shows example blocks of process600, in some implementations, process600may include additional blocks, fewer blocks, different blocks, or differently arranged blocks than those depicted inFIG.6. Additionally, or alternatively, two or more of the blocks of process600may be performed in parallel.

FIG.7is a flowchart of an example process700associated with accessing a transport carrier. In some implementations, one or more process blocks ofFIG.7may be performed by a multiple transport carrier docking device (e.g., the multiple transport carrier docking device108). In some implementations, one or more process blocks ofFIG.7may be performed by another device or a group of devices separate from or including the multiple transport carrier docking device, such as a semiconductor processing tool102, a load port104, an interface tool106, and/or another device. Additionally, or alternatively, one or more process blocks ofFIG.7may be performed by one or more components of device500, such as processor520, memory530, storage component540, input component550, output component560, and/or communication component570.

As shown inFIG.7, process700may include retrieving, using a wafer transport tool, a wafer from a semiconductor processing tool (block710). For example, the interface tool may retrieve, using the wafer transport tool124, the wafer404from the semiconductor processing tool102, as described above.

As further shown inFIG.7, process700may include providing, using the wafer transport tool, the wafer to a transport carrier positioned on a moveable platform of a plurality of moveable platforms included in a first chamber of a multiple transport carrier docking device while a first air-tight seal is formed around the transport carrier by a sealing component of the multiple transport carrier docking device (block720). For example, the interface tool106may provide, using the wafer transport tool124, the wafer404to the transport carrier112positioned on the moveable platform146of the plurality of moveable platforms146included in the first chamber130of the multiple transport carrier docking device108while a first air-tight seal is formed around the transport carrier112by the sealing component152of the multiple transport carrier docking device108, as described above.

As further shown inFIG.7, process700may include placing a carrier door onto the transport carrier while the first air-tight seal is around the front portion of the transport carrier (block730). For example, the multiple transport carrier docking device108may place (e.g., using the chamber door138) the carrier door116onto the transport carrier112while the first air-tight seal is around the front portion of the transport carrier112, as described above.

As further shown inFIG.7, process700may include placing a chamber door against divider wall between the first chamber and a second chamber of the multiple transport carrier docking device to close an opening in the divider wall and to form a second air-tight seal between the chamber door and the divider wall (block740). For example, the multiple transport carrier docking device108may place the chamber door138against the divider wall134between the first chamber130and the second chamber132of the multiple transport carrier docking device108to close the opening136in the divider wall134and to form a second air-tight seal between the chamber door138and the divider wall134, as described above.

As further shown inFIG.7, process700may include retracting the sealing component to remove the first air-tight seal around the transport carrier after the second air-tight seal is formed (block750). For example, the multiple transport carrier docking device108may retract the sealing component152to remove the first air-tight seal around the transport carrier112after the second air-tight seal is formed, as described above.

Process700may include additional implementations, such as any single implementation or any combination of implementations described below and/or in connection with one or more other processes described elsewhere herein.

In a first implementation, process700includes moving the plurality of moveable platforms146in the first chamber130such that another transport carrier112on another movable platform146of the plurality of moveable platforms146is positioned in front of the opening136in the divider wall134, contracting the sealing component152around the other transport carrier112to form a third air-tight seal around the other transport carrier112, after forming the third air-tight seal around the other transport carrier112removing another carrier door116of the other transport carrier112, and opening the chamber door138to remove the second air-tight seal to permit access to the other transport carrier112through the opening136in the divider wall134, and accessing, using the wafer transport tool124, the other transport carrier112while the third air-tight seal is around the other transport carrier112.

AlthoughFIG.7shows example blocks of process700, in some implementations, process700may include additional blocks, fewer blocks, different blocks, or differently arranged blocks than those depicted inFIG.7. Additionally, or alternatively, two or more of the blocks of process700may be performed in parallel.

In this way, a multiple transport carrier docking device may be positioned between a load port and an interface tool to reduce and/or minimize cross contamination of semiconductor wafers that are transferred between the load port and an associated semiconductor processing tool. The multiple transport carrier docking device may be capable of storing and/or staging a plurality of transport carriers in a chamber of the multiple transport carrier docking device, and may be capable of forming an air-tight seal around a transport carrier in the chamber. Semiconductor wafers in the transport carrier may be accessed by a transport tool while the air-tight seal around the transport carrier prevents and/or reduces the likelihood that contaminants in the semiconductor fabrication facility will reach the semiconductor wafers. The air-tight seal around the transport carrier may reduce defects of the semiconductor wafers that might otherwise be caused by the contaminants, may increase manufacturing yield and quality in the semiconductor fabrication facility, and/or may permit the continued reduction in device and/or feature sizes of integrated circuits and/or semiconductor devices that are to be formed on semiconductor wafers.

As described in greater detail above, some implementations described herein provide a multiple transport carrier docking device. The multiple transport carrier docking device includes a first chamber configured to store a plurality of transport carriers. The multiple transport carrier docking device includes a second chamber. The multiple transport carrier docking device includes a divider wall between the first chamber and the second chamber. where the divider wall includes an opening between the first chamber and the second chamber. The multiple transport carrier docking device includes a chamber door configured to form an air-tight seal against the divider wall and around the opening.

As described in greater detail above, some implementations described herein provide a method. The method includes positioning a transport carrier on a moveable platform of a plurality of moveable platforms included in a first chamber of a multiple transport carrier docking device. The method includes contracting a sealing component of the multiple transport carrier docking device around the transport carrier to form an air-tight seal around the transport carrier. The method includes after forming the air-tight seal around the transport carrier removing a carrier door of the transport carrier, and opening a chamber door of the multiple transport carrier docking device to permit access to the transport carrier through an opening in a divider wall between the first chamber and a second chamber of the multiple transport carrier docking device. The method includes accessing, using a wafer transport tool associated with the multiple transport carrier docking device, the transport carrier while the air-tight seal is around the transport carrier.

As described in greater detail above, some implementations described herein provide a multiple transport carrier docking device. The multiple transport carrier docking device includes a first chamber configured to store a plurality of transport carriers. The multiple transport carrier docking device includes a second chamber adjacent to the first chamber. The multiple transport carrier docking device includes a divider wall between the first chamber and the second chamber, where the divider wall includes an opening between the first chamber and the second chamber. The multiple transport carrier docking device includes a chamber door, included in the second chamber, configured to form a first air-tight seal against the divider wall and around the opening. The multiple transport carrier docking device includes a sealing component, included in the first chamber, configured to form a second air-tight seal between the first chamber and a transport carrier in the first chamber.

As described in greater detail above, some implementations described herein provide a method. The method includes retrieving, using a wafer transport tool, a wafer from a semiconductor processing tool. The method includes providing, using the wafer transport tool, the wafer to a transport carrier positioned on a moveable platform of a plurality of moveable platforms included in a first chamber of a multiple transport carrier docking device while a first air-tight seal is formed around the transport carrier by a sealing component of the multiple transport carrier docking device. The method includes placing a carrier door onto the transport carrier while the first air-tight seal is around the front portion of the transport carrier. The method includes placing a chamber door against a divider wall between the first chamber and a second chamber of the multiple transport carrier docking device to close an opening in the divider wall and to form a second air-tight seal between the chamber door and the divider wall. The method includes retracting the sealing component to remove the first air-tight seal around the transport carrier after the second air-tight seal is formed.

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.