Patent ID: 12191165

DETAILED DESCRIPTION

The following disclosure provides several 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 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 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 illustrated 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. Also, relationship terms such as “connected to,” “adjacent to,” “coupled to,” and the like, may be used herein to describe both direct and indirect relationships. “Directly” connected, adjacent, or coupled may refer to a relationship in which there are no intervening components, devices, or structures. “Indirectly” connected, adjacent, or coupled may refer to a relationship in which there are intervening components, devices, or structures.

A wafer transfer system and method, such as including a load lock module, and method of using, operating, etc. are provided. According to some embodiments, the wafer transfer system provides a particle (PA) shield, such as by developing an air/gas channel within a transfer chamber of the system. Particle (PA) protection is provided to a wafer during transfer of the wafer, such as in a load lock module, to fabrication equipment during semiconductor manufacturing. The wafer, such as a semiconductor wafer, is processed to develop semiconductor devices thereon/therefrom which are used in a multitude of electronic devices, such as mobile phones, laptops, desktops, tablets, watches, gaming systems, and various other industrial, commercial, and consumer electronics. A semiconductor wafer generally undergoes one or more treatments to produce desired semiconductor devices, features, etc. The wafer is transferred in a transfer chamber, such as within a load lock module, between different pieces of semiconductor fabrication equipment as the wafer undergoes semiconductor processing or manufacturing. According to some embodiments, one or more gas nozzles or structures provide a gas shield around the wafer in a wafer container, such as a transfer chamber of a wafer load lock module. The gas shield surrounds the wafer while the wafer is transferred between different pieces of semiconductor fabrication equipment. The one or more gas nozzles or structures guide gas within the transfer chamber away from the wafer. The gas may contain particles, which are also guided away from the wafer. An air supply system and/or a controller provide different angles of the air nozzles and/or air flow speeds through the nozzles to create the air shield. The air shield mitigates contact between particles and the wafer and/or serves to evacuate particles from the system/module. Mitigating contact between particles and the wafer and/or evacuating particles is desirable because the particles can contaminate the wafer and adversely affect the operation, reliability, etc. of devices formed in/on the wafer and thereby reduce yield, increase costs, etc.

FIG.1is a schematic illustration of a wafer transfer system100for transferring a wafer, according to some embodiments. For example, the wafer transfer system100comprises a processing chamber102connected to a load lock module104. The processing chamber102includes a stage106to support a wafer108, such as a semiconductor wafer, for processing. The processing chamber102may be any type of wafer processing chamber that provides wafer processing, such as wet clean processing (e.g., cleaning by solvents such as acetone, trichloroethylene and ultrapure water), surface passivation, photolithography, ion implantation (e.g., embedding dopants in regions of the wafer108), etching (e.g., dry etching, plasma etching, reactive-ion etching (RIE), atomic layer etching (ALE), buffered oxide etching), plasma ashing, thermal treatments (e.g., rapid thermal anneal, furnace anneals, thermal oxidation), vapor deposition (e.g., chemical vapor deposition (CVD), atomic layer deposition (ALD), physical vapor deposition (PVD)), molecular beam epitaxy (MBE), electrochemical deposition (ECD), chemical-mechanical polishing (CMP), etc. The processing chamber102may also be a wafer transfer tool, such as a cluster tool, that transfers the wafer108into another processing chamber or another component of a processing chamber. The processing chamber102may be a front opening unified pod (FOUP), which is an enclosure configured to hold a plurality of wafers in a controlled environment and to facilitate transfer to other processing or measurement equipment. According to an example, the processing chamber102is shown as a CVD chamber that receives source reactive materials and carrier gas110from an ancillary processing chamber112for processing the wafer108.

In some embodiments, the load lock module104is configured to mechanically transfer the wafer108into and out of the processing chamber102, to generally approximate conditions within the processing chamber102, to mitigate introduction of media, such as dust, moisture, condensation, contaminants, etc., into the processing chamber102, and/or to reduce loss of processing materials used to process the wafer108within the processing chamber. The load lock module104includes a transfer chamber105defining a volume. The transfer chamber includes a wafer support114within the volume to support the wafer108. The wafer support114may be configured as a robotic arm to transfer the wafer108into and/or out of the processing chamber102. For example, the wafer support114may place the wafer108onto the stage106of the processing chamber102and/or retrieve the wafer108from the stage106of the processing chamber102. In an example, the processing chamber102may include a robotic arm to transfer the wafer108from a structure, such as a stage or the wafer support114, within the load lock module104. In an example, the load lock module104includes the wafer support114configured as a cassette or carousel for storing and/or transferring a plurality of wafers including the wafer108. The load lock module104includes a first load port116, such as including an insulated and retractable door, to facilitate transfer of the wafer108and to insulate the transfer chamber105of the load lock module104from exterior conditions. In an example, the load lock module includes a second load port118to facilitate transfer of the wafer108, such as transfer to a second processing chamber (not shown). During transfer of the wafer108, the wafer support114passes through the first load port116of the load lock module104and a first load port of the processing chamber102.

In some embodiments, the environment and operation of the load lock module104is controlled by a controller120. According to some embodiments, the controller120includes a pressure control unit122, a nozzle direction unit124, a gas sensing unit126, a temperature sensing and control unit128, and/or a support control unit130. In some embodiments, the pressure control unit122changes and/or maintains pressure within the transfer chamber105of the load lock module104. The pressure control unit122may change pressure within the transfer chamber105in accordance with pressure within the processing chamber102. The transfer chamber105may be associated with an atmospheric pressure, such as a standard atmosphere (1 atm). Pressure within the transfer chamber105may be changed to facilitate transfer to the processing chamber102. In an example where the processing chamber102provides atmospheric pressure CVD (APCVD), the transfer chamber105may be maintained at 1 atm. In an example where the processing chamber102provides low-pressure CVD (LPCVD), such as thermal oxide deposition, the transfer chamber105may be reduced to sub-atmospheric pressures, such as in range from 10−4Torr to 1 Torr. In an example where the processing chamber102provides ultrahigh vacuum CVD (UHVCVD), the transfer chamber105may be reduced to a very low pressure, such as below 10−8Torr. In an example where the processing chamber102provides sub-atmospheric CVD (SACVD), the transfer chamber105may be increased and/or maintained above 30 Torr, such as between 100-600 Torr. In an example, the load lock module104is ventilated with Nitrogen gas to ambient pressure or a small overpressure during transfer of the wafer108into and/or out of the load lock module104.

In some embodiments, the pressure control unit122regulates pressure within the transfer chamber105by controlling a supply of gas from a gas supply unit132. Gas from the gas supply unit132flows through a pressure valve134and then through a plurality of conduits, such as pneumatic hoses, to a first input nozzle valve136aand/or a second input nozzle valve136b. The first input nozzle valve136acommunicates gas through a conduit, such as a pneumatic hose, to a first input gas nozzle138a, which is housed in a first input nozzle assembly140a. Likewise, the second input nozzle valve136bcommunicates gas through a conduit, such as a pneumatic hose, to a second input gas nozzle138b, which is housed in a second input nozzle assembly140b. In an example, the first input gas nozzle138adirects a first flow of gas above the wafer support114and the second input gas nozzle138bdirects a second flow of gas below the wafer support114. Gas from within the transfer chamber105is guided out of the transfer chamber105by a first output gas nozzle142a, which is housed in a first output nozzle assembly144a. Gas from within the transfer chamber105is also guided out of the transfer chamber105by a second output gas nozzle142b, which is housed in a second output nozzle assembly144b. In an example, the first output gas nozzle142aguides the first flow of gas above the wafer support114and the second output gas nozzle142bguides the second flow of gas below the wafer support114. Gas is suctioned from the first output gas nozzle142a, thorough a conduit, such as a pneumatic hose, connected to a first output nozzle valve146aby an exhaust pump148. Gas is also suctioned from the second output gas nozzle142b, thorough a conduit, such as a pneumatic hose, connected to a second output nozzle valve146bby the exhaust pump148and/or a different exhaust pump (not shown).

According to some embodiments, the pressure control unit122controls the exhaust pump148and/or at least one of the first output nozzle valve146aor the second output nozzle valve146bto create a vacuum environment within the transfer chamber105by way of suction of gas through at least one of the first output gas nozzle142aor the second output gas nozzle142b. For example, upon introduction of the wafer108into the load lock module104, the environment within the transfer chamber105may be changed or maintained to a transfer chamber pressure in accordance with pressure of the processing chamber102, such as APCVD, LPCVD, UHVCVD, or SACVD, as set forth above. In some embodiments, the pressure control unit122controls the pressure valve134, the first input nozzle valve136a, and the second input nozzle valve136bin closed positions to not introduce gas into the transfer chamber105until a predetermined transfer chamber pressure is reached. The pressure control unit122may control the first output nozzle valve146ato open less than the second output nozzle valve146bto create a first flow speed of the first flow of gas less than a second flow speed of the second flow of gas through suction of existing gas from the transfer chamber105. In some embodiments, the pressure control unit122controls the pressure valve134, the first input nozzle valve136a, and the second input nozzle valve136bin open positions less than at least one of the first output nozzle valve146aor the second output nozzle valve146b. The first flow of gas and the second flow of gas are simultaneously created and/or maintained within the transfer chamber105while the transfer chamber pressure is changed through suction of existing gas from the transfer chamber105at a rate greater than introduction of gas into the transfer chamber105. In some embodiments, the pressure control unit122provides a cleaning cycle by creating turbulent air within the transfer chamber105by dynamically changing gas flow through the first input nozzle valve136a, the second input nozzle valve136b, the first output nozzle valve146a, and/or the second output nozzle valve146b. The turbulent air may entrain media within gas inside the transfer chamber105, which is in turn suctioned through the first output gas nozzle142aand the second output gas nozzle142bat a rate greater than introduction of gas into the transfer chamber105. For example, a cleaning cycle may be initiated by the pressure control unit122periodically and/or before introduction of the wafer108into the transfer chamber105to remove contaminants from the volume defined within the transfer chamber. In an example, a cleaning cycle may be initiated with the wafer108disposed on the wafer support114before and/or after processing of the wafer108by the processing chamber102.

According to some embodiments, the first input gas nozzle138aand the first output gas nozzle142aform a first set of gas nozzles disposed above the wafer support114within the transfer chamber105. In some embodiments, the first set of gas nozzles provides a laminar flow of gas above the wafer support114in layers, such that each layer moves smoothly past adjacent layers with little to no mixing. According to some embodiments, the second input gas nozzle138band the second output gas nozzle142bform a second set of gas nozzles disposed below the wafer support114within the transfer chamber105. In some embodiments, the second set of gas nozzles provides a laminar flow of gas below the wafer support114in layers, such that each layer moves smoothly past adjacent layers with little to no mixing.

In some embodiments, the pressure control unit122of the controller120regulates the pressure valve134and/or the first input nozzle valve136ato control a flow speed of the gas supplied by the gas supply unit132to the first input gas nozzle138a. The pressure control unit122of the controller120regulates the pressure valve134and/or the first input nozzle valve136ato control a first flow speed of the first flow of gas input into the transfer chamber105by the first input gas nozzle138a. According to some embodiments, the first flow speed of the first flow of gas input into the transfer chamber105corresponds to the first flow speed of the first flow of gas above the wafer support114. In some embodiments, the pressure control unit122of the controller120regulates the pressure valve134and/or the second input nozzle valve136bto control a flow speed of the gas supplied by the gas supply unit132to the second input gas nozzle138b. The pressure control unit122of the controller120regulates the pressure valve134and/or the second input nozzle valve136bto control a second flow speed of the second flow of gas input into the transfer chamber105by the second input gas nozzle138b. According to some embodiments, the second flow speed of the second flow of gas input into the transfer chamber105corresponds to the second flow speed of the second flow of gas below the wafer support114. According to some embodiments, the pressure control unit122of the controller120regulates the first input nozzle valve136aand/or the second input nozzle valve136bsuch that the first flow speed of the first flow of gas is less than the second flow speed of the second flow of gas. When gas moves faster, pressure of the moving gas decreases. When the first flow speed of the first flow of gas, such as above the wafer support114, is less than the second flow speed of the second flow of gas, such as below the wafer support114, a downforce, also known as downward air pressure or negative lift, is created within the transfer chamber105. The downforce directs media, such as dust, moisture, condensation, contaminants, etc. downward and away from the wafer support114and/or the wafer108. The downforce also inhibits dislodging of the wafer108from the wafer support114.

The downforce within the transfer chamber105follows Bernoulli's principle, which states that an increase in speed of a fluid, such as the second flow speed of the second flow of gas greater than the first flow speed of the first flow of gas, occurs simultaneously with a decrease in static pressure or a decrease in the fluid's potential energy. Bernoulli's principle is summarized in equation 1, as follows:
P+pgh+½·pv2=constant  Equation 1
where P is fluid pressure, p is fluid density, g is the acceleration due to gravity, h is the height of elevation, and v is fluid velocity. Thus, if the speed of a fluid decreases not due to an elevation difference, then the decrease in speed is due to an increase in static pressure that is resisting the fluid flow. In other words, an increase in speed v is accompanied by a simultaneous decrease in pressure P in order for the sum to add up to the same constant number. Thus, an increase in the second flow speed of the second flow of gas greater than the first flow speed of the first flow of gas within the transfer chamber105creates a downforce within the transfer chamber105.

In some embodiments, the temperature sensing and control unit128controls temperature within the transfer chamber105to facilitate transfer of the wafer108to the processing chamber102. The temperature sensing and control unit128communicates with a heating element150to control a temperature of the gas supplied by the gas supply unit132. The temperature sensing and control unit128communicates with the heating element150to control a temperature of the first flow of gas input into the transfer chamber105by the first input gas nozzle138a. In an example where the processing chamber102provides atmospheric pressure CVD (APCVD), the transfer chamber105may be changed or maintained above 100° C., such as between 600 and 800° C. In an example where the processing chamber102provides low-pressure CVD (LPCVD), the transfer chamber105may be changed or maintained greater than ambient room temperature (i.e., 15 to 25° C.), such as between 125 and 250° C. In an example where the processing chamber102provides ultrahigh vacuum CVD (UHVCVD), the transfer chamber105may be changed or maintained above 500° C., such as between 500 and 600° C. In an example where the processing chamber102provides sub-atmospheric CVD (SACVD), the transfer chamber105may be changed and/or maintained above 300° C., such as between 350 and 500° C. In some embodiments, the temperature sensing and control unit128controls a temperature of the wafer108itself to facilitate transfer of the wafer108with the processing chamber102. Temperature of the wafer108may be changed in accordance with processing within the processing chamber102. In an example, the heating element150is an infra-red heating element that directs infra-red radiation towards the wafer108for absorption and heating thereof. Other arrangements and/or configurations of the load lock module104, the controller120, the heating element150, and/or the gas supply unit132are within the scope of the present disclosure.

FIG.2Ais a schematic illustration of the wafer transfer system100for transferring a wafer andFIG.2Bis an enhanced illustration of the load lock module104ofFIG.2A, according to some embodiments. The wafer transfer system100is illustrated without the wafer support114for clarity. The wafer transfer system100is configured as a portable transfer system that may be arranged for connection to various processing equipment, such as the processing chamber102ofFIG.1. The wafer transfer system100includes a cart structure202that may support and contain various components, such as the controller120, the gas supply unit132, the exhaust pump148, valves, and/or conduits, which are illustrated in an exploded view for clarity. The load lock module104includes a door204that may be opened for manual insertion of a wafer, such as the wafer108, and/or configuration of internal components.

As illustrated inFIGS.2A and2B, gas from the gas supply unit132flows through the pressure valve134and then through a plurality of conduits, such as pneumatic hoses, to a third input nozzle valve136cand a fourth input nozzle valve136d. The third input nozzle valve136ccommunicates gas through a conduit, such as a pneumatic hose, to a third input gas nozzle138c, which is housed in a third input nozzle assembly140c. The fourth input nozzle valve136dcommunicates gas through a conduit, such as a pneumatic hose, to a fourth input gas nozzle138d, which is housed in a fourth input nozzle assembly140d. In an example, the third input gas nozzle138cdirects a third flow of gas above the wafer support114(not shown) and the fourth input gas nozzle138ddirects a fourth flow of gas below the wafer support114(not shown). Gas from within the transfer chamber105is guided out of the transfer chamber105by a third output gas nozzle142c, which is housed in a third output nozzle assembly144c. Gas from within the transfer chamber105is guided out of the transfer chamber105by a fourth output gas nozzle142d, which is housed in a fourth output nozzle assembly144d. In an example, the third output gas nozzle142cguides the third flow of gas above the wafer support114(not shown) and the fourth output gas nozzle142dguides the fourth flow of gas below the wafer support114(not shown). Gas is suctioned from the third output gas nozzle142cthorough a conduit, such as a pneumatic hose, to a third output nozzle valve146c, and then through a conduit, such as a pneumatic hose, connected to the exhaust pump148. Gas is suctioned from the fourth output gas nozzle142dthrough a conduit, such as a pneumatic hose, to a fourth output nozzle valve146d, and then through a conduit, such as a pneumatic hose, connected to the exhaust pump148. In some embodiments, each of the input nozzle valves136a-dcontrols a corresponding input flow speed of gas through a corresponding input gas nozzle and each of the output nozzle valves146a-dcontrols a corresponding output flow speed of gas through a corresponding output gas nozzle in response to control by the pressure control unit122. For example, the first input nozzle valve136acontrols a first input flow speed, the second input nozzle valve136bcontrols a second input flow speed, the third input nozzle valve136ccontrols a third input flow speed, and the fourth input nozzle valve136dcontrols a fourth input flow speed. For example, the first output nozzle valve146acontrols a first output flow speed, the second output nozzle valve146bcontrols a second output flow speed, the third output nozzle valve146ccontrols a third output flow speed, and the fourth output nozzle valve146dcontrols a fourth output flow speed. Other arrangements and/or configurations of the input nozzle valves136a-dand/or the output nozzle valves146a-dare within the scope of the present disclosure.

In an example, the third input gas nozzle138cand the third output gas nozzle142cform a third set of gas nozzles disposed above the wafer support114(not shown) within the transfer chamber105. In some embodiments, the third set of gas nozzles provides a laminar flow of gas above the wafer support114(not shown) in layers, such that each layer moves smoothly past adjacent layers with little to no mixing. According to some embodiments, the fourth input gas nozzle138dand the fourth output gas nozzle142dform a fourth set of gas nozzles disposed below the wafer support114(not shown) within the transfer chamber105. In some embodiments, the fourth set of gas nozzles provides a laminar flow of gas below the wafer support114(not shown) in layers, such that each layer moves smoothly past adjacent layers with little to no mixing. Other arrangements and/or configurations of the input gas nozzles, the input nozzle valves, the output gas nozzles, and/or the output nozzle valves are within the scope of the present disclosure.

FIG.3is a schematic illustration of the wafer transfer system100for transferring a wafer, according to some embodiments. The pressure control unit122of the controller120regulates the pressure valve134and/or an input nozzle valve302to control a flow speed of the gas supplied by the gas supply unit132to an input gas nozzle304, which is housed in an input nozzle assembly305. The pressure control unit122of the controller120regulates the pressure valve134and/or the input nozzle valve302to control a first flow speed of a first flow of gas306within the transfer chamber105and/or a second flow speed of a second flow of gas308. Gas from within the transfer chamber105is guided out of the transfer chamber105by an output gas structure310and suctioned by the exhaust pump148. In an embodiment, the output gas structure310is a geometric structure having a first sidewall312aand a second sidewall312b. For example, the first sidewall312aand the second sidewall312bare angled toward the wafer support114to facilitate laminar airflow of the first flow of gas306and the second flow of gas308. In an embodiment, the output gas structure310includes a plurality of baffles, also known as diverters or chutes, to direct a channel of laminar airflow out of the transfer chamber105. An air shield314and a downforce are created around the wafer support114and the wafer108by the first flow of gas306and/or the second flow of gas308to direct particles, media, contaminants, etc. away from the wafer support114and the wafer108, and is thus at times referred to as a PA shield. A physical arrangement of the input gas nozzle304and the output gas structure310within the transfer chamber105and below the wafer support114promotes the first flow speed of the first flow of gas306to be less than the second flow speed of the second flow of gas308. Other arrangements and/or configurations of the input gas nozzle304and/or the output gas structure310are within the scope of the present disclosure.

According to some embodiments, the gas sensing unit126communicates with a first pressure sensor316aand/or a second pressure sensor316b, disposed within the transfer chamber105. The first pressure sensor316aand/or the second pressure sensor316bmeasure at least one of the first flow speed of the first flow of gas306, the second flow speed of the second flow of gas308, or the transfer chamber pressure within the transfer chamber105. In an example, the first pressure sensor316aand/or the second pressure sensor316bincludes a Pirani heat loss gauge and/or an atmospheric reference gauge to measure the transfer chamber pressure and to provide a set-point control signal once a vacuum pressure between the load lock module104and the processing chamber102is equalized. A Pirani heat loss gauge may be configured as a thin metal wire, such as Nickel, suspended in a tube connected to the transfer chamber105. The thin metal wire may change in electrical potential across a Wheatstone bridge circuit in response to transfer chamber pressure, which in turn is communicated to the gas sensing unit126. In an example, the first pressure sensor316aand/or the second pressure sensor316bmay be configured as a micro-electro-mechanical system (MEMS) Pirani vacuum transducer. A gauge sensor may offer advantages over an absolute sensor in vacuum environments because the transfer chamber pressure may be more accurately equalized to zero differential pressure between the transfer chamber105and ambient pressure independently of variation in barometric ambient pressure due to changes in weather conditions. In an example, the first pressure sensor316aand/or the second pressure sensor316bincludes a capacitance manometer to measure absolute or relative pressure within the transfer chamber105. In an example, the first pressure sensor316aand/or the second pressure sensor316bincludes a Pirani gauge and a capacitance monometer. A Pirani gauge may read about 60% higher than a capacitance manometer in the presence of water vapor, such that the difference in measurement may be detected by the gas sensing unit126and communicated to the pressure control unit122to regulate introduction of a reactively neutral gas into the transfer chamber105, such as Helium, Nitrogen, and/or Argon. Other arrangements and/or configurations of the first pressure sensor316aand/or the second pressure sensor316bare within the scope of the present disclosure.

FIGS.4A-4Care schematic illustrations of the wafer transfer system100for transferring a wafer, according to some embodiments.FIG.4Ais a side view illustrating the wafer support114in a retracted position,FIG.4Bis a plan view illustrating the wafer support114in the retracted position, andFIG.4Cis a plan view illustrating the wafer support114in an extended position. The temperature sensing and control unit128communicates with a first temperature sensor402aand/or a second temperature sensor402b, disposed within the transfer chamber105. The first temperature sensor402aand/or the second temperature sensor402bmeasure at least one of a temperature of gas within the transfer chamber105or a temperature of the wafer108. In an example, the first temperature sensor402aand/or the second temperature sensor402bincludes a resistance thermometer (RTD) and/or a thermocouple. A thermocouple may be configured as a plurality of conductors enclosed within a mineral insulated cable. The mineral may be a highly compressed powder made of a metal oxide (e.g., magnesium oxide (MgO) and/or aluminum oxide (Al2O3)). According to an embodiment, the first temperature sensor402aand/or the second temperature sensor402bmay be the same as the first pressure sensor316aand/or the second pressure sensor316band calibrated to respond to temperature and pressure. The temperature sensing and control unit128then responds to the measured temperature to control the heating element150to increase temperature within the transfer chamber105. The temperature sensing and control unit128may respond to the measured temperature and decrease the temperature within the transfer chamber105. The temperature sensing and control unit128communicates with the pressure control unit122to increase the first flow of gas306and the second flow of gas308input into the transfer chamber105and/or to increase suction of gas from the transfer chamber105by the exhaust pump148. Other arrangements and/or configurations of the temperature sensing and control unit128, the first temperature sensor402a, and/or the second temperature sensor402bare within the scope of the present disclosure.

According to some embodiments, the nozzle direction unit124of the controller120communicates with the input nozzle assemblies140a-dto control a direction of gas input by corresponding input gas nozzles138a-dinto the transfer chamber105. The nozzle direction unit124communicates with the output nozzle assemblies144a-dto control a direction of gas output by corresponding output gas nozzles142a-dfrom the transfer chamber105. By controlling the input nozzle assemblies140a-dand/or the output nozzle assemblies144a-d, the nozzle direction unit124controls a direction of gas flow within the transfer chamber105. The nozzle direction unit124controls a first direction, such as about the Y-axis, of one or a plurality of the input gas nozzles138a-dabout a first axis of rotation to control a direction of gas flow within the transfer chamber. For example, the nozzle direction unit124controls the first direction of the first input gas nozzle138aand the third input gas nozzle138cto control a direction of the first flow of gas306within the transfer chamber105. The nozzle direction unit124controls the first direction of the second input gas nozzle138band the fourth input gas nozzle138dto control a direction of the second flow of gas308within the transfer chamber105. In an example, the first input gas nozzle138aand the third input gas nozzle138care controlled to provide a first degree of change in the first direction, such as 15, 30, 45, −15, −30, −45 degrees, etc. The second input gas nozzle138band the fourth input gas nozzle138dare controlled to provide a second degree of change in the first direction, such as 15, 30, 45, −15, −30, −45 degrees, etc. According to an example, the first degree of change is approximately equal to the second degree of change. According to an example, the first degree of change is approximately opposite to the second degree of change. The first degree of change may be a positive degree of change, such as 15, 30, 45, etc., and the second degree of change may be a negative degree of change, such as −15, −30, −45, etc. In some embodiments, the nozzle direction unit124controls a second direction, such as about the X-axis, of one or a plurality of the input gas nozzles138a-dabout a second axis of rotation to control a direction of gas flow within the transfer chamber.

According to some embodiments, the nozzle direction unit124dynamically controls the first direction, such as about the Y-axis, of one or a plurality of the input gas nozzles138a-d. For example, the nozzle direction unit124dynamically controls the first direction of the first input gas nozzle138aand the third input gas nozzle138cto dynamically change about the first degree of change in the first direction, such as 15, 30, 45, −15, −30, −45 degrees, etc. The nozzle direction unit124dynamically controls the second input gas nozzle138band the fourth input gas nozzle138dto dynamically change about the second degree of change in the first direction, such as 15, 30, 45, −15, −30, −45 degrees, etc. According to an example, the first degree of dynamic change is approximately equal to the second degree of dynamic change such that all input gas nozzles138a-dcycle in synchronism. According to an example, the first degree of dynamic change is approximately opposite to the second degree of dynamic change such that the first input gas nozzle138aand the third input gas nozzle138ccycle in synchronism with each other and the second input gas nozzle138band the fourth input gas nozzle138dcycle in synchronism with each other and opposite to the first input gas nozzle138aand the third input gas nozzle138c. In some embodiments, the nozzle direction unit124dynamically controls a second direction, such as about the X-axis, of one or a plurality of the input gas nozzles138a-dto control a direction of gas flow within the transfer chamber.

According to some embodiments, the nozzle direction unit124controls the output nozzle assemblies144a-din the first direction, such as about the Y-axis, and/or the second direction, such as about the X-axis, to thereby control the first direction and the second direction of the output gas nozzles142a-din like manner to the input gas nozzles138a-dset forth above. In an example, the nozzle direction unit124controls the first direction of the first input gas nozzle138aand the third input gas nozzle138cto be approximately equal to the direction of the first output gas nozzle142aand the third output gas nozzle142c. In an example, the first direction of the first input gas nozzle138aand the third input gas nozzle138cis approximately opposite to the direction of the first output gas nozzle142aand the third output gas nozzle142c. Input gas nozzles138b,138dand output gas nozzles142b,142dmay be controlled in like manner to input gas nozzles138a,138cand output gas nozzles142a,142d.

According to some embodiments, the nozzle direction unit124controls the input gas nozzles138a-dand the output gas nozzles142a-dto dynamically change in the first direction, such a about the Y-axis, and/or the second direction, such as about the X-axis. In an example, the input gas nozzles138a-dand the output gas nozzles142a-dcycle in synchronism in at least one of the first direction, the second direction, or the first and the second direction. In an example, the input gas nozzles138a,138cand the output gas nozzles142a,142ccycle in synchronism in at least one of the first direction, the second direction, or the first and the second direction, while the input gas nozzles138b,138dand the output gas nozzles142b,142dcycle in synchronism in at least one of the first direction, the second direction, or the first and the second direction. Other arrangements and/or configurations for controlling the input gas nozzles138a-dand/or the output gas nozzles142a-dare within the scope of the present disclosure.

According to some embodiments, the support control unit130controls the wafer support114to robotically transfer the wafer108into and/or out of the transfer chamber105. With reference to the plan view ofFIG.4B, the wafer support114is illustrated in the retracted position. The wafer support includes a spindle404mechanically connected to a receiver406by a first linkage408and a second linkage410. As the spindle404rotates, the first linkage408and the second linkage410translate the rotational motion of the spindle404into linear motion of the receiver406. In an example, the wafer108may be manually placed onto the receiver406. With reference to the plan view ofFIG.4C, the receiver406may be controlled to traverse through the first load port116or the second load port118to load the wafer108into processing equipment, such as the stage106within the processing chamber102. Other arrangements and/or configurations of the support control unit130and/or the wafer support114are within the scope of the present disclosure.

FIGS.5A-5Care schematic illustrations of the wafer transfer system100for transferring a wafer, according to some embodiments.FIG.5Ais a side view of the load lock module104,FIG.5Bis a plan view taken along line5B-5B ofFIG.5A, andFIG.5Cis a plan view taken along line5C-5C ofFIG.5A. A first plurality of input gas nozzles502a-eare disposed above the wafer support114and a second plurality of input gas nozzles504a-eare disposed below the wafer support114. A first plurality of output gas nozzles506a-eare disposed above the wafer support114and a second plurality of output gas nozzles508a-eare disposed below the wafer support114. Each of the first plurality of input gas nozzles502a-eand the second plurality of input gas nozzles504a-eare moveable about the first direction and/or the second direction by corresponding input nozzle assemblies, such as controlled by the nozzle direction unit124, and are supplied with gas by corresponding input nozzle valves (not shown), such as controlled by the pressure control unit122. Likewise, each of the first plurality of output gas nozzles506a-eand the second plurality of output gas nozzles508a-eare moveable about the first direction and/or the second direction by corresponding output nozzle assemblies, such as controlled by the nozzle direction unit124, and are supplied with gas by corresponding output nozzle valves (not shown), such as controlled by the pressure control unit122.

According to some embodiments, a first set of input gas nozzles and a second set of input gas nozzles are defined from the first plurality of input gas nozzles502a-eand the second plurality of input gas nozzles504a-e. For example, the first set of input gas nozzles may include input gas nozzles502c,504cand the second set of input gas nozzles may include input gas nozzles502b,502d,504b,504d. According to some embodiments, a first set of output gas nozzles and a second set of output gas nozzles are defined from the first plurality of output gas nozzles506a-eand the second plurality of output gas nozzles508a-e. For example, the first set of output gas nozzles may include output gas nozzles506c,508cand the second set of output gas nozzles may include output gas nozzles506b,506d,508b,508d. According to some embodiments, the first set of input gas nozzles and the first set of output gas nozzles are controlled by the pressure control unit122to regulate the transfer chamber pressure. According to some embodiments, the second set of input gas nozzles and the second set of output gas nozzles are controlled by the pressure control unit122to generate at least one of the first flow of gas306and/or the second flow of gas308.

According to some embodiments, the first set of the input gas nozzles and a first set of the output gas nozzles are controlled in like manner to the input gas nozzles138a-dand the output gas nozzles142a-dset forth above. For example, the first set of the input gas nozzles are positioned about at least one of the first direction, such as about the Y-axis, or the second direction, such as about the X-axis, to coincide with the first set of the output gas nozzles. In an example, the first set of the input gas nozzles are positioned about at least one of the first direction or the second direction opposite to the first set of the output gas nozzles. In an example, the first set of the input gas nozzles are controlled to dynamically change about at least one of the first direction or the second direction in synchronism with controlled dynamic change of the first set of the output gas nozzles about at least one of the first direction or the second direction. In an example, the first set of the input gas nozzles are controlled to dynamically change about at least one of the first direction or the second direction in synchronism with and opposite to controlled dynamic change of the first set of the output gas nozzles about at least one of the first direction or the second direction.

According to some embodiments, the second set of the input gas nozzles and a second set of the output gas nozzles are controlled in like manner to the input gas nozzles138a-dand the output gas nozzles142a-dset forth above. For example, the second set of the input gas nozzles are positioned about at least one of the first direction, such as about the Y-axis, or the second direction, such as about the X-axis, to coincide with the second set of the output gas nozzles. In an example, the second set of the input gas nozzles are positioned about at least one of the first direction or the second direction opposite to the second set of the output gas nozzles. In an example, the second set of the input gas nozzles are controlled to dynamically change about at least one of the first direction or the second direction in synchronism with controlled dynamic change of the second set of the output gas nozzles about at least one of the first direction or the second direction. In an example, the second set of the input gas nozzles are controlled to dynamically change about at least one of the first direction or the second direction in synchronism with and opposite to controlled dynamic change of the second set of the output gas nozzles about at least one of the first direction or the second direction.

According to some embodiments, the first plurality of input gas nozzles502a-eare positioned about at least one of the first direction, such as about the Y-axis, or the second direction, such as about the X-axis, to coincide with the first plurality of output gas nozzles506a-e. In some embodiments, the first plurality of input gas nozzles502a-eare positioned about at least one of the first direction or the second direction to be opposite to the first plurality of output gas nozzles506a-e. In some embodiments, the first plurality of input gas nozzles502a-eare controlled to dynamically change about at least one of the first direction or the second direction in synchronism with controlled dynamic change of the second plurality of input gas nozzles504a-e. In some embodiments, the first plurality of input gas nozzles502a-eare controlled to dynamically change about at least one of the first direction or the second direction in synchronism with and opposite to controlled dynamic change of the second plurality of input gas nozzles504a-e. In some embodiments, the first plurality of output gas nozzles506a-eand the second plurality of output gas nozzles508a-eare controlled in like manner to the first plurality of input gas nozzles502a-eand the second plurality of input gas nozzles504a-e, as set forth above. Other arrangements and/or configurations of the first plurality of input gas nozzles502a-e, the second plurality of input gas nozzles504a-e, the first plurality of output gas nozzles506a-e, and/or the second plurality of output gas nozzles508a-eare within the scope of the present disclosure.

FIGS.6A-6Eare schematic illustrations of a nozzle assembly600, according to some embodiments. The nozzle assembly600is an example nozzle assembly corresponding to any one or more of the above mentioned nozzle assemblies, such as140a-d,144a-d,305. The nozzle assembly600is configured to control and/or dynamically control a position of a nozzle, such as138a-d,142a-d,304,502a-e,504a-e,506a-e,508a-e, about at least one of the first direction, such as about the Y-axis, or the second direction, such as about the X-axis. The nozzle assembly600responds to control signals from the nozzle direction unit124, in some embodiments.FIG.6Ais a side view,FIG.6Bis a plan view,FIG.6Cis a front view, andFIG.6Dis a rear view of the nozzle assembly600. As illustrated, the nozzle assembly600includes a nozzle602secured into a ball structure604by external threads606. The ball structure604is rotatable about a first axis and/or a second axis. The ball structure604defines a channel605to pass gas to the nozzle602. The ball structure604moves within a socket608about the Y-axis in response to linear motion of a first lever arm610and about the X-axis in response to linear motion of a second lever arm612. The ball structure604includes a rear plate614defining a first lever socket616and a second lever socket618. A ball end of the first lever arm610is received within the first lever socket and a ball end of the second lever arm612is received within the second lever socket618. The first lever arm610is moved linearly in response to a Y-axis motor620and a position of the first lever arm610is determined by a Y-axis sensor622. Linear motion of the first lever arm610translates into rotational movement of the ball structure604about the Y-axis. The second lever arm612is moved linearly in response to an X-axis motor624and a position of the second lever arm612is determined by an X-axis sensor626. Linear motion of the second lever arm612translates into rotational movement of the ball structure604about the X-axis. The Y-axis motor620, the Y-axis sensor622, the X-axis motor624, and the X-axis sensor626communicate with and respond to commands from the nozzle direction unit124by way of an interface628.FIG.6Eis a side view of the nozzle assembly600illustrating connection of a conduit630, such as a pneumatic hose, to rear external threads632of the ball structure604. Other arrangements and/or configurations of the nozzle assembly600are within the scope of the present disclosure.

FIG.7is a diagram of example components of a device700, according to some embodiments. The device700may correspond to the controller120. As illustrated inFIG.7, the device700may include a bus710, a processor720, a memory730, a storage component740, an input component750, an output component760, and a communication interface770. The bus710includes a component that permits communication among the components of the device700. The processor720is implemented in hardware, firmware, or a combination of hardware and software. The processor720is a central processing unit (CPU), a graphics processing unit (GPU), an accelerated processing unit (APU), a microprocessor, a microcontroller, a digital signal processor (DSP), a field-programmable gate array (FPGA), an application-specific integrated circuit (ASIC), or another type of processing component. In some implementations, the processor720includes one or more processors capable of being programmed to perform a function. The memory730includes a random access memory (RAM), a read only memory (ROM), and/or another type of dynamic or static storage device (e.g., a flash memory, a magnetic memory, and/or an optical memory) that stores information and/or instructions for use by the processor720.

The storage component740stores information and/or software related to the operation and use of the device700. For example, the storage component740may include a hard disk (e.g., a magnetic disk, an optical disk, a magneto-optic disk, and/or a solid state disk), a compact disc (CD), a digital versatile disc (DVD), a floppy disk, a cartridge, a magnetic tape, and/or another type of non-transitory computer-readable medium, along with a corresponding drive. The input component750includes a component that permits the device700to receive information, such as via user input (e.g., a touch screen display, a keyboard, a keypad, a mouse, a button, a switch, and/or a microphone). Additionally, or alternatively, the input component750may include a sensor for sensing information (e.g., a global positioning system (GPS) component, an accelerometer, a gyroscope, and/or an actuator). The output component760includes a component that provides output information from device700(e.g., a display, a speaker, and/or one or more light-emitting diodes (LEDs)). The communication interface770includes a transceiver-like component (e.g., a transceiver and/or a separate receiver and transmitter) that enables the device700to communicate with other devices, such as via a wired connection, a wireless connection, or a combination of wired and wireless connections. The communication interface770may permit the device700to receive information from another device and/or provide information to another device. For example, the communication interface770may include an Ethernet interface, an optical interface, a coaxial interface, an infrared interface, a radio frequency (RF) interface, a universal serial bus (USB) interface, a Wi-Fi interface, a cellular network interface, and/or the like.

The device700may perform one or more processes described herein. The device700may perform these processes based on the processor720executing software instructions stored by a non-transitory computer-readable medium, such as the memory730and/or the storage component740. A computer-readable medium is defined herein as a non-transitory memory device. A memory device includes memory space within a single physical storage device or memory space spread across multiple physical storage devices. Software instructions may be read into the memory730and/or the storage component740from another computer-readable medium or from another device via the communication interface770. When executed, software instructions stored in the memory730and/or the storage component740may cause the processor720to perform one or more processes described herein. Additionally, or alternatively, hardwired circuitry may be used in place of or in combination with software 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 the components shown inFIG.7are provided as an example. In practice, the device700may include additional components, fewer components, different components, or differently arranged components than those shown inFIG.7. Additionally, or alternatively, a set of components (e.g., one or more components) of device700may perform one or more functions described as being performed by another set of components of the device700.

FIG.8illustrates an example method800, in accordance with some embodiments. Some of the operations described can be replaced and/or eliminated for different embodiments. At802, a first flow of gas is input into a transfer chamber above a wafer support. The first flow of gas is at least one of the first flow of gas306or other flow of gas. The transfer chamber is at least one of the transfer chamber105or other suitable transfer chamber and the wafer support is at least one of the wafer support114or other suitable structure. At804, a second flow of gas is input into the transfer chamber below the wafer support. The second flow of gas is at least one of the second flow of gas308or other flow of gas. At806, a first flow speed of the first flow of gas is controlled to be different than a second flow speed of a second flow of gas. At808, at least one of a first or a second direction of the first flow of gas is controlled within the transfer chamber. The first direction is at least one of a direction with respect to a Y-axis or other suitable axis and the second direction is at least one of a direction with respect to an X-axis or other suitable axis. At810, at least one of a first or a second direction of a second flow of gas is controlled within transfer chamber.

According to some embodiments, a wafer transfer system is provided. The wafer transfer system includes a transfer chamber defining a volume and the transfer chamber includes a wafer support within the volume to support a wafer. A first input gas nozzle is disposed above the wafer support within the transfer chamber and inputs a first flow of gas into the transfer chamber at a first flow speed. A second input gas nozzle is disposed below the wafer support within the transfer chamber and inputs a second flow of gas into the transfer chamber at a second flow speed different than the first flow speed. A first output gas structure guides the gas from the transfer chamber due to the second flow speed being different than the first flow speed such that suspended particles within the transfer chamber are at least one of directed away from the wafer support or directed toward the first output gas structure to guide the suspended particles from the transfer chamber.

According to some embodiments, a method of shielding in a wafer transport system is provided. The method includes inputting, by a first input gas nozzle, a first flow of gas into a transfer chamber including a wafer support to support a wafer, above the wafer support. The method includes inputting, by a second input gas nozzle, a second flow of gas into the transfer chamber below the wafer support. The method includes supplying, by a gas supply unit, gas to the first input gas nozzle and the second input gas nozzle. The method includes controlling, by a controller, at least one of a first flow speed of the first flow of gas input into the transfer chamber or a second flow speed of the gas supplied by the gas supply unit to the first input gas nozzle. The method includes controlling, by the controller at least one of a third flow speed of the second flow of gas input into the transfer chamber different than the first flow speed or a fourth flow speed of the gas supplied by the gas supply unit to the second input gas nozzle different than the second flow speed.

According to some embodiments, a method of shielding in a wafer transport system is provided. The method includes inputting, by a first input gas nozzle, a first flow of gas into a transfer chamber comprising a wafer support to support a wafer, above the wafer support. The method includes inputting, by a second input gas nozzle, a second flow of gas into the transfer chamber below the wafer support. The method includes controlling, by a controller, at least one of a first direction of the first flow of gas input into the transfer chamber or a second direction of the second flow of gas input into the transfer chamber such that suspended particles within the transfer chamber are at least one of directed away from the wafer support or directed toward a first output gas structure to guide the suspended particles from the transfer chamber.

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 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.

Although the subject matter has been described in language specific to structural features or methodological acts, it is to be understood that the subject matter of the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing at least some of the claims.

Various operations of embodiments are provided herein. The order in which some or all of the operations are described should not be construed to imply that these operations are necessarily order dependent. Alternative ordering will be appreciated having the benefit of this description. Further, it will be understood that not all operations are necessarily present in each embodiment provided herein. Also, it will be understood that not all operations are necessary in some embodiments.

It will be appreciated that layers, features, elements, etc. depicted herein are illustrated with particular dimensions relative to one another, such as structural dimensions or orientations, for example, for purposes of simplicity and ease of understanding and that actual dimensions of the same differ substantially from that illustrated herein, in some embodiments. Additionally, a variety of techniques exist for forming the layers, regions, features, elements, etc. mentioned herein, such as at least one of etching techniques, planarization techniques, implanting techniques, doping techniques, spin-on techniques, sputtering techniques, growth techniques, or deposition techniques such as CVD, for example.

Moreover, “exemplary” is used herein to mean serving as an example, instance, illustration, etc., and not necessarily as advantageous. As used in this application, “or” is intended to mean an inclusive “or” rather than an exclusive “or”. In addition, “a” and “an” as used in this application and the appended claims are generally to be construed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form. Also, at least one of A and B and/or the like generally means A or B or both A and B. Furthermore, to the extent that “includes”, “having”, “has”, “with”, or variants thereof are used, such terms are intended to be inclusive in a manner similar to the term “comprising”. Also, unless specified otherwise, “first,” “second,” or the like are not intended to imply a temporal aspect, a spatial aspect, an ordering, etc. Rather, such terms are merely used as identifiers, names, etc. for features, elements, items, etc. For example, a first element and a second element generally correspond to element A and element B or two different or two identical elements or the same element.

Also, although the disclosure has been shown and described with respect to one or more implementations, equivalent alterations and modifications will occur to others of ordinary skill in the art based upon a reading and understanding of this specification and the annexed drawings. The disclosure comprises all such modifications and alterations and is limited only by the scope of the following claims. In particular regard to the various functions performed by the above described components (e.g., elements, resources, etc.), the terms used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure. In addition, while a particular feature of the disclosure may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application.