Vertically-stacked process reactor and cluster tool system for atomic layer deposition
First Claim
1. A low-profile, compact, atomic layer deposition reactor (LP-CAR), comprising:
- a body having a length, a width, and a height, the height equal to or less than either the width or length, wherein the length and height define first and second sides opposite one another, and the width and height define first and second ends opposite one another;
a substrate processing region within the body, adapted to enclose a substrate during processing;
a load/unload port in the first side, the load/unload port opening to the substrate processing region and adapted for passing a substrate into and out of the substrate processing region;
a retractable support pedestal extendable into the substrate processing region in the direction of the height, for supporting a substrate during processing;
a remotely-operable vacuum valve connected to the first side, the vacuum valve adapted to open and close the load/unload opening executing a vacuum seal in the closed position;
an inlet adapted for injecting a gas or vapor at the first end; and
an exhaust exit adapted for evacuating gas and vapor at the second end.
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Abstract
A low profile, compact atomic layer deposition reactor (LP-CAR) has a low-profile body with a substrate processing region adapted to serve a single substrate or a planar array of substrates, and a valved load and unload port for substrate loading and unloading to and from the LP-CAR. The body has an inlet adapted for injecting a gas or vapor at the first end, and an exhaust exit adapted for evacuating gas and vapor at the second end. The LP-CAR has an external height no greater than any horizontal dimension, and more preferably no more than two-thirds any horizontal dimension, facilitating a unique system architecture. An internal processing region is distinguished by having a vertical extent no greater than one fourth the horizontal extent, facilitating fast gas switching. In some embodiments one substrate at a time is processed, and in other embodiments there may be multiple substrates arranged in the processing region in a planar array. The compact reactor is distinguished by individual injectors, each of which comprise a charge tube formed between a charge valve and an injection valve. The charge valve connects the charge tube to a pressure regulated supply, and the injection valve opens the charge tube into the compact reactor. Rapidly cycling the valves injects fixed mass-charges of gas or vapor into the compact reactor. Multiple such compact reactors are stacked vertically, interfaced into a vacuum handling region having a Z-axis robot and a load/unload opening.
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Citations
25 Claims
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1. A low-profile, compact, atomic layer deposition reactor (LP-CAR), comprising:
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a body having a length, a width, and a height, the height equal to or less than either the width or length, wherein the length and height define first and second sides opposite one another, and the width and height define first and second ends opposite one another; a substrate processing region within the body, adapted to enclose a substrate during processing; a load/unload port in the first side, the load/unload port opening to the substrate processing region and adapted for passing a substrate into and out of the substrate processing region; a retractable support pedestal extendable into the substrate processing region in the direction of the height, for supporting a substrate during processing; a remotely-operable vacuum valve connected to the first side, the vacuum valve adapted to open and close the load/unload opening executing a vacuum seal in the closed position; an inlet adapted for injecting a gas or vapor at the first end; and an exhaust exit adapted for evacuating gas and vapor at the second end. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A low-profile, compact, atomic layer deposition reactor (LP-CAR), comprising:
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a body having a length, a width, and a height, wherein the length and height define first and second sides opposite one another, and the width and height define first and second ends opposite one another; a substrate processing region within the body, adapted to enclose a substrate during processing; an inlet adapted for injecting a gas or vapor at the first end; and an exhaust exit adapted for evacuating gas and vapor at the second end; wherein the gas inlet comprises one or more valved charge tubes for injecting one of a gas or vapor into the substrate processing region, each charge tube comprising a volume closed at one end by a remotely operable charge valve and at the other end by a remotely operable injection valve, the end having the injection valve being connected to the gas inlet, such that with the injection valve closed and the charge valve open to a source of gas or vapor under pressure the charge tube may be charged with a specific mass of the gas or vapor, and with the charge valve closed and the injection valve open the specific mass of gas or vapor may be expended into the substrate processing region. - View Dependent Claims (12, 13, 14)
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15. A vertically-stacked compact atomic layer deposition reactor (VESCAR) processing unit, comprising:
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a vacuum handling region having a valved load/unload opening adapted for transferring substrates to be processed into and out of the vacuum handling region; a plurality of low profile, compact atomic layer deposition reactors (LP-CARs), each interfaced into the vacuum handling region by a valved substrate port, the plurality of LP-CARS arranged in a vertical stack one-above-the-other outside the vacuum handling region, such that the valved substrate ports of the compact reactors present a substantially vertical column of ports within the vacuum handling region; and a z-axis robot in the vacuum handling region; wherein the z-axis robot is adapted to accept substrates transferred into the vacuum handling region by a transfer apparatus through the valved load/unload opening, to travel vertically to the level of each of the substrate ports, to extend to place substrates to and to receive substrates from each of the compact reactors through each of the valved substrate ports, and to place processed substrates on the transfer apparatus to be transferred through the load/unload port out of the vacuum handling region. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
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Specification