Automated Replacement of Consumable Parts Using Interfacing Chambers
First Claim
1. A loadlock chamber disposed within a cluster tool assembly used for processing a substrate, the cluster tool assembly having an atmospheric transfer module, a vacuum transfer module and a process module, the loadlock chamber disposed between the atmospheric transfer module and the vacuum transfer module, the loadlock chamber comprising:
- a support mechanism having a plurality of finger assemblies, each one of the plurality of finger assemblies includes a top support finger and a bottom support finger, the top and the bottom support fingers having a first end and a second end, a top surface of the bottom support finger includes an indent defined proximal to the second end and between the first end and the second end;
a spacer block disposed between the top support finger and the bottom support finger at the first end,a second spacer block disposed below the bottom support finger at the first end;
a substrate contact pad is disposed on the top surface of the top and the bottom support fingers at the second end proximal to a tip of the top and bottom support fingers; and
a consumable contact pad is disposed in the indent, the consumable contact pad being disposed between the substrate contact pad disposed in the bottom support finger and the first end of the bottom support finger,wherein the plurality of finger assemblies are configured to transport both a consumable part using the consumable contact pad and a substrate using the substrate contact pad.
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Accused Products
Abstract
A cluster tool assembly includes a vacuum transfer module, a process module having a first side connected to the vacuum transfer module. An isolation valve having a first side and a second side, the first side of the isolation valve coupled to a second side of the process module. A replacement station is coupled to the second side of the isolation valve. The replacement station includes an exchange handler and a part buffer. The part buffer includes a plurality of compartments to hold new or used consumable parts. The process module includes a lift mechanism to enable placement of a consumable part installed in the process module to a raised position. The raised position provides access to the exchange handler to enable removal of the consumable part from the process module and store in a compartment of the part buffer. The exchange handler of the replacement station is configured to provide a replacement for the consumable part from the part buffer back to the process module. The lift mechanism is configured to receive the consumable part provided for replacement by the exchange handler and lower the consumable part to an installed position. The replacement by the exchange handler and the process module is conducted while the process module and the replacement station are maintained in a vacuum state.
95 Citations
24 Claims
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1. A loadlock chamber disposed within a cluster tool assembly used for processing a substrate, the cluster tool assembly having an atmospheric transfer module, a vacuum transfer module and a process module, the loadlock chamber disposed between the atmospheric transfer module and the vacuum transfer module, the loadlock chamber comprising:
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a support mechanism having a plurality of finger assemblies, each one of the plurality of finger assemblies includes a top support finger and a bottom support finger, the top and the bottom support fingers having a first end and a second end, a top surface of the bottom support finger includes an indent defined proximal to the second end and between the first end and the second end; a spacer block disposed between the top support finger and the bottom support finger at the first end, a second spacer block disposed below the bottom support finger at the first end; a substrate contact pad is disposed on the top surface of the top and the bottom support fingers at the second end proximal to a tip of the top and bottom support fingers; and a consumable contact pad is disposed in the indent, the consumable contact pad being disposed between the substrate contact pad disposed in the bottom support finger and the first end of the bottom support finger, wherein the plurality of finger assemblies are configured to transport both a consumable part using the consumable contact pad and a substrate using the substrate contact pad. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A cluster tool assembly having an atmospheric transfer module, a vacuum transfer module, a loadlock chamber and a process module, the cluster tool assembly comprising:
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the atmospheric transfer module having a first robot; a replacement station coupled to a first side of the atmospheric transfer module, the replacement station having a part buffer with a plurality of compartments to store new or used consumable parts; a loadlock chamber coupled to a second side of the atmospheric transfer module and a first side of the vacuum transfer module, the loadlock chamber providing an interface between the atmospheric transfer module and the vacuum transfer module; and wherein the first robot includes a first end-effector mechanism, the first end-effector mechanism of the first robot includes, a wrist plate; a mounting armset connected to the wrist plate; a finger assembly mounted to the mounting armset and includes a pair of fingers extending outward from the mounting armset, the finger assembly having a proximal end proximal to the mounting armset and a distal end defined at tips of the pair of fingers; a first carrier contact pad disposed on a top surface of the finger assembly proximal to a center of a fork defined by the pair of fingers; and a second pair of carrier contact pads disposed on the top surface of the finger assembly and located proximal to the distal end of the finger assembly, wherein the finger assembly is configured to transport a substrate and support a carrier plate using the first carrier and the second pair of carrier contact pads, wherein the carrier plate is configured to support a consumable part. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
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24. A cluster tool assembly used for processing a substrate, the cluster tool assembly having an atmospheric transfer module, a vacuum transfer module, a loadlock chamber and a process module, the cluster tool assembly comprising:
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a replacement station coupled to a first side of the atmospheric transfer module, the replacement station having a part buffer with a plurality of compartments to store new or used consumable parts; the loadlock chamber coupled to a second side of the atmospheric transfer module and a first side of the vacuum transfer module, the loadlock chamber providing an interface between the atmospheric transfer module and the vacuum transfer module, the loadlock chamber comprising; a support mechanism having a plurality of finger assemblies, each one of the plurality of finger assemblies includes a top support finger and a bottom support finger, the top and the bottom support fingers having a first end and a second end, a top surface of the bottom support finger includes an indent defined proximal to the second end and between the first end and the second end; a first spacer block disposed between the top support finger and the bottom support finger at the first end, a second spacer block disposed below the bottom support finger at the first end; a substrate contact pad is disposed on the top surface of the top and the bottom support fingers at the second end proximal to a tip of the top and bottom support fingers; and a consumable contact pad is disposed in the indent, the consumable contact pad being disposed between the substrate contact pad disposed in the bottom support finger and the first end of the bottom support finger, wherein the plurality of finger assemblies are configured to transport both a consumable part using the consumable contact pad and a substrate using the substrate contact pad.
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Specification