Patent ID: 12253218

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof, and in which are shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” etc., is used with reference to the orientation of the Figure(s) being described. The components of the present invention can be positioned in a number of different orientations. As such, the directional terminology is used for purposes of illustration and is in no way limiting. On the other hand, the drawings are only schematic and the sizes of components may be exaggerated for clarity. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. Similarly, the terms “facing,” “faces” and variations thereof herein are used broadly and encompass direct and indirect facing, and “adjacent to” and variations thereof herein are used broadly and encompass directly and indirectly “adjacent to”. Therefore, the description of “A” component facing “B” component herein may contain the situations that “A” component directly faces “B” component or one or more additional components are between “A” component and “B” component. Also, the description of “A” component “adjacent to” “B” component herein may contain the situations that “A” component is directly “adjacent to” “B” component or one or more additional components are between “A” component and “B” component. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.

FIG.1is a schematic diagram of a gas filling docking tray according to an embodiment of the invention. As shown inFIG.1, the gas filling docking tray100may include a carrier substrate110, a plurality of guide blocks120, and a plurality of positioning pins130. The carrier substrate110is provided with a base surface112, and the plurality of guide blocks120are disposed on a peripheral area of the base surface112to define a wafer carrier accommodation area R, and the guide blocks120are at least disposed on two opposite sides of the base surface112. In this embodiment, the guide blocks120are disposed around the base surface112, and each guide block120has a bending structure B, but the invention is not limited thereto. The positioning pins130are disposed in the wafer carrier accommodation area R of the carrier substrate110, and the function of the positioning pins130is to engage with a wafer carrier (not shown) to confine the wafer carrier in a predetermined position. In this embodiment, the number of positioning pins130is three, and the positioning pins130may be arranged in a triangular configuration in the accommodation area R to more firmly fix the wafer carrier in a correct inflation position, but the invention is not limited thereto. Each guide block120includes a vertical portion120asubstantially perpendicular to the base surface112and an inclined portion120blocated above and connected with the vertical portion120a. In one embodiment, an angle α between the inclined portion120band a normal line N of the base surface112may range from 10 degrees to 70 degrees. In this embodiment, a height T of the apex of the positioning pin130relative to the base surface112is greater than a height h of the apex of the vertical portion120aof the guide block120relative to the base surface112, and the height T is smaller than the height H of the apex of the inclined portion120bof the guide block120relative to the base surface112. Please also refer toFIG.2, where multiple guide blocks120are disposed on the base surface112to define a wafer carrier accommodation area R. By the above height difference designs of the vertical portion120aand the inclined portion120bof the guide block120relative to the positioning pin130, during the process of positioning the wafer carrier160in the accommodation area R, the wafer carrier160can be first guided by the inclined portion120bto touch the positioning pin130, and then fallen along the vertical portion120ato completely engage with the positioning pin130. This allows to smooth the process of placing the wafer carrier160on the base surface112and ensure each part of the guide block120to function properly. In one embodiment, the wafer carrier160may be, but is not limited to, a front opening unified pod (FOUP). Furthermore, in one embodiment, the inclined portion120bmay include a chamfer r as shown inFIG.2. In addition, in one embodiment, the base surface112may have adjustment holes112acorresponding to the guide blocks120, and the shape of the adjustment holes112amay be elongated, with the length of the elongated hole being greater than its width. If necessary, the adjustment holes112acan cooperate with fastening members such as screws (not shown) to adjust the position of the guide block120on the base surface112to a limited extent.

Referring toFIG.1again, in this embodiment, at least one pair of fixed nozzles142(two pairs of fixed nozzles142are shown inFIG.1) and at least one pair of retractable nozzles144are provided in the wafer carrier accommodation area R. The fixed nozzles142may function as inlet ports142aand outlet ports142b, and the retractable nozzles144may function as an inlet port144aand an outlet port144b. The fixed nozzles142and the retractable nozzles144are in fluid communication with different gas channels to deliver clean gas into the wafer carrier160. Clean gas may be, for example, pure dry air (CDA), extremely pure dry air (X-CDA), or inert gas (such as nitrogen). In this embodiment, a height h1of the apex of the fixed nozzle142relative to the base surface112is smaller than a height h of the apex of the vertical portion120aof the guide block120relative to the base surface112. Furthermore, a height h2of the apex of the retractable nozzle144relative to the base surface112is smaller than the height T of the apex of the positioning pin130relative to the base surface112, and the height h2is greater than the height h1of the apex of the fixed nozzle142relative to the base surface112. By the above height difference designs among the fixed nozzles142, the retractable nozzles144, the positioning pins130and the vertical portion120aof the guide block120, during the process of guiding the wafer carrier160by the guide block120, engaging the wafer carrier160onto the positioning pins130and communicating the wafer carrier160with the nozzles142and144, the possibility that the moving wafer carrier160interferes with other components such as nozzles can be reduced. This may result in a smoother movement of the wafer carrier160and ensure airtightness and positioning reliability during gas filling. Furthermore, it should be noted a bottom mechanism (not shown) of a wafer carrier160suitable for fixed nozzles142is different to a bottom mechanism (not shown) of the wafer carrier160suitable for retractable nozzles144. Therefore, when a wafer carrier160having a bottom mechanism suitable for fixed nozzles142is placed on the carrier substrate110, the retractable nozzles144, due to the retractable characteristic, would not interfere with the movement of such wafer carrier160.

FIG.3shows a schematic diagram of a wafer carrier mounted on a gas filling docking tray according to an embodiment of the invention. As shown inFIG.3, the wafer carrier160such as a front opening unified pod (FOUP) is inserted onto the positioning pins130by the guidance of the guide blocks120. The inclined surface of the inclined portion120bof each guide block120may assist the wafer carrier160to slide smoothly, and then the height difference of the vertical portion120aof each guide block120may precisely make the wafer carrier160fall onto the positioning pins130. The guiding effect generated by the inclined surface and vertical surface of the guide block120can avoid abnormal gas inflation caused by positional errors between nozzles and wafer carrier160in loading and unloading goods. Besides, by the height relationships set among the fixed nozzles142, the retractable nozzles144, the positioning pins130, the vertical portions120aand the inclined portions120bof the guide blocks120, the positioning process of the wafer carrier160can be smoother, and airtightness and positioning reliability during gas filling can be further ensured. The guide blocks120may be made of a plastic material such as polyoxymethylene, ultra-high molecular weight polyethylene (UPE), polytetrafluoroethylene or acrylic, but the invention is not limited thereto. In one embodiment, as shown inFIG.3, the bottom160aof the wafer carrier160that has been positioned on the carrier substrate110is more than 1 mm below the apex of the vertical portion120aof each guide block120.

Furthermore, the guide blocks120only need to be provided on at least two opposite sides of the base surface112of the carrier substrate110and to have both vertical and inclined portions for guiding the wafer carrier160, but the number, size, shape, distribution and position of the guide blocks120may vary according to actual needs without limitation. As shown inFIG.4A, a plurality of guide blocks120of the gas filling docking tray100A may have a linear symmetrical distribution on the carrier substrate110. Furthermore, as shown inFIG.4B, in another embodiment, the guide block120provided on the gas filling docking tray100B may be a columnar body without a bending structure.

The gas filling docking tray according to various embodiments of the invention can be used in various types of transportation module or system for transportation semiconductor material without limitation. In one embodiment, the gas filling docking tray100can be provided in an overhead transport system, such as being used in an overhead hoist buffer (OHB), an under track storage (UTS), or a side track Buffer (STB). For example, as shown inFIG.5, in an overhead hoist buffer200, the gas filling docking tray100is installed at the bottom of a plurality of vertical rods202. The wafer carrier160transported by an overhead hoist transport (OHT) (not shown) is placed on the gas filling docking tray100, and an inflation/exhaust module210connects nozzles of the gas filling docking tray100to inflate the wafer carrier160and thus replace the air inside the wafer carrier160with clean gas to meet required process standards. A control module220is electrically connected with the inflation/exhaust module210to control the operation of the inflation/exhaust module210to exchange gas in the wafer carrier160, and the control module220may detect and monitor the gas pressure, flow rate, temperature, humidity, oxygen concentration and other parameters of the pipeline. In other embodiment, the gas filling docking tray100may be provided in a ground workstation such as a standalone purge station or a dummy load port. For example,FIG.6shows the configuration of the gas filling docking tray100in a standalone purge station300. As shown inFIG.6, the gas filling docking tray100is disposed beside the process equipment far from the warehouse storage system to inflate the wafer carrier (not shown) placed on the gas filling docking tray100and thus provide the effect of, for example, removing moisture and oxygen.FIG.7is a block diagram of a gas filling device according to an embodiment of the invention, and the gas filling device can be used in a standalone purge station, a dummy load port, an overhead hoist buffer (OHB), an under track storage (UTS) or a side track Buffer (STB) without limitation. As shown inFIG.7, the gas filling device400includes an inflation module410, an exhaust module420, a control module430, and a gas filling docking tray100. The inflation module410is connected to an inlet port140aof the gas filling docking tray100to inflate the wafer carrier160, and the exhaust module420is connected to the outlet port140bof the gas filling docking tray100to allow the gas inside the wafer carrier160to be discharged outward. The control module430is electrically connected to the inflation module410and the exhaust module420to control the operation of the inflation module410and the exhaust module420. In one embodiment, the inflation module410may include a gas supply411, a pressure valve412, a pressure sensor413, a mass flow controller (MFC)414, a solenoid valve415, and an air filter416. The pressure valve412regulates the gas pressure of the gas from the gas supply411to the inflation pipeline, the pressure sensor413detects the gas pressure in the inflation pipeline, the mass flow controller414automatically controls the gas flow rate based on preset values to achieve a stable flow, and the air filter416filters out particles or specific molecules in the gas entering the wafer carrier160. The control module430may control on/off operations of the solenoid valve415to selectively block the flow of gas into the wafer carrier160. The exhaust module420may include an exhaust unit421, a negative pressure generator422, a pressure sensor423, a flow meter424, a temperature and humidity sensor425, and a solenoid valve426. The exhaust unit421can be controlled by the control module430to discharge the gas inside the wafer carrier160outward. The control module430may controls on/off operations of the solenoid valve426to selectively block the gas discharge. The negative pressure generator422may create a negative pressure in the exhaust pipeline to accelerate the discharge of gas. For example, the negative pressure generator422may be a vacuum generator. The flow meter424detects the gas flow rate through the exhaust pipeline, the pressure sensor423detects the gas pressure in the exhaust pipeline, and the temperature and humidity sensor425detects the humidity and temperature of the gas in the exhaust pipeline to monitor the gas state inside the wafer carrier160. In one embodiment, other detectors (such as detectors for detecting the concentration, acidity, and alkalinity of specific gases) may be included, and the control module430may control the gas exchange inside the wafer carrier160based on the signals transmitted by various detectors. The control module430may be a circuit board with a microprocessor, but the invention is not limited thereto.

According to the above embodiments, the inclined portion may cooperate with the vertical portion of the guide block to guide a wafer carrier to a preset position during the process of positioning the wafer carrier on a gas filling docking tray, thereby avoiding abnormal gas inflation caused by loading and unloading positional errors. Moreover, by setting height relationships among the positioning pin, the vertical portion and the inclined portion of the guide block, the process of placing the wafer carrier onto a carrier substrate can be smoother and ensure proper functioning of each part of the guide block. Additionally, by adjusting the height relationships among the fixed nozzles, retractable nozzles, positioning pin, vertical portion and inclined portion of the guide block, the positioning process of the wafer carrier can be smoother, and airtightness and positioning reliability during gas filling can be further ensured.

The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form or to exemplary embodiments disclosed. Accordingly, the foregoing description should be regarded as illustrative rather than restrictive. Obviously, many modifications and variations will be apparent to practitioners skilled in this art. The embodiments are chosen and described in order to best explain the principles of the invention and its best mode practical application, thereby to enable persons skilled in the art to understand the invention for various embodiments and with various modifications as are suited to the particular use or implementation contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents in which all terms are meant in their broadest reasonable sense unless otherwise indicated. Therefore, the term “the invention”, “the present invention” or the like does not necessarily limit the claim scope to a specific embodiment, and the reference to particularly preferred exemplary embodiments of the invention does not imply a limitation on the invention, and no such limitation is to be inferred. The invention is limited only by the spirit and scope of the appended claims. Moreover, these claims may refer to use “first”, “second”, etc. following with noun or element. Such terms should be understood as a nomenclature and should not be construed as giving the limitation on the number of the elements modified by such nomenclature unless specific number has been given. The abstract of the disclosure is provided to comply with the rules requiring an abstract, which will allow a searcher to quickly ascertain the subject matter of the technical disclosure of any patent issued from this disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Any advantages and benefits described may not apply to all embodiments of the invention. It should be appreciated that variations may be made in the embodiments described by persons skilled in the art without departing from the scope of the present invention as defined by the following claims. Moreover, no element and component in the present disclosure is intended to be dedicated to the public regardless of whether the element or component is explicitly recited in the following claims.