Temperature control of individual tools in a cluster tool system
First Claim
1. A system for controlling the temperature levels of a number of tools deployed in a cluster and providing different fabrication functions for a product being manufactured, comprising:
- a single refrigeration unit providing subcooled pressurized refrigerant and including a single compressor having capacity adequate for chilling all the tools concurrently desired individual levels;
a pressurized reservoir for thermal transfer fluid;
a source of unchilled coolant;
a plurality of control channels, each including heat exchanger means, a fluid pump, and fluid heater means disposed to define a separate thermal transfer fluid loop in communication with a different tool, and with the thermal transfer fluid reservoir, the control channels comprising at least first and second types, control channels of a first type each having its heat exchanger means coupled to receive the subcooled refrigerant from the refrigeration unit and controllable evaporator means coupled to supply refrigerant to the associated heat exchanger means, control channels of the second type being coupled to receive the unchilled coolant at the heat exchanger means therein; and
regulator means responsive to the temperature of the different tools and coupled to operate the control channels to provide thermal transfer fluid in each channel at a temperature to maintain each respective tool at its selected temperature level.
6 Assignments
0 Petitions
Accused Products
Abstract
A temperature control unit for independent control of a number of independent channels, as can exist with a cluster tool used for semiconductor fabrication, has high efficiency, long term life and reliability, and requires only a small floor area. To these ends, the unit employs a single high capacity refrigeration system and disposes a number of separate temperature control channels for the individual tools, with only some channels receiving refrigerant. Low temperature channels use high pressure, sub-cooled refrigerant for chilling the heat transfer fluid to selected levels controlled by proportional valves adjusting refrigerant flow through evaporator heat exchanger units which cool heat transfer fluid. Moderate temperature channels cool the heat transfer fluid for associated tools to an ambient temperature level. The tools may, as needed, be heated by elements in the separate control channels, the control levels for both cooling and heating being determined by servo circuits programmed to measure actual and establish desired temperature levels.
3 Citations
56 Claims
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1. A system for controlling the temperature levels of a number of tools deployed in a cluster and providing different fabrication functions for a product being manufactured, comprising:
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a single refrigeration unit providing subcooled pressurized refrigerant and including a single compressor having capacity adequate for chilling all the tools concurrently desired individual levels;
a pressurized reservoir for thermal transfer fluid;
a source of unchilled coolant;
a plurality of control channels, each including heat exchanger means, a fluid pump, and fluid heater means disposed to define a separate thermal transfer fluid loop in communication with a different tool, and with the thermal transfer fluid reservoir, the control channels comprising at least first and second types, control channels of a first type each having its heat exchanger means coupled to receive the subcooled refrigerant from the refrigeration unit and controllable evaporator means coupled to supply refrigerant to the associated heat exchanger means, control channels of the second type being coupled to receive the unchilled coolant at the heat exchanger means therein; and
regulator means responsive to the temperature of the different tools and coupled to operate the control channels to provide thermal transfer fluid in each channel at a temperature to maintain each respective tool at its selected temperature level. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A control loop system for maintaining the temperature of an operating tool at a selected level within a substantial temperature range that includes levels above and below the ambient, using a chilled pressurized refrigerant and a thermal transfer fluid, comprising:
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means defining a control loop for a thermal transfer fluid communicating in thermal interchange relation with the tool, the loop further including pump means for the thermal transfer fluid;
electrical heater means disposed in the control loop between the pump and tool and controllable in response to an energizing temperature control signal;
heat exchanger means in the loop and receiving the thermal transfer fluid and the chilled refrigerant;
proportional valve means coupled to receive the chilled refrigerant in the heat exchanger means for controlling the flow of chilled refrigerant in the heat exchanger means such as to maintain a selected below ambient temperature in the thermal transfer fluid transferred to the tool, and means coupled to the heater means for controlling the heater means to alternatively maintain a selected temperature level that is above the ambient in the thermal transfer fluid. - View Dependent Claims (12, 13, 14, 16, 17, 18, 19, 20)
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15. A system for separately controlling the temperature of a number of controlled units using heat transfer fluid and comprising:
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a supply reservoir providing pressurized heat transfer fluid;
a single refrigeration unit providing high pressure refrigerant;
a number of conduit loops receiving refrigerant from the refrigeration unit and heat transfer fluid from the reservoir and coupled to circulate heat transfer fluid through the associated controlled unit, each of the conduit loops also including an evaporator receiving the refrigerant from the refrigeration unit and a heat exchanger for interchanging thermal energy between the heat transfer fluid and the refrigerant;
servo control means for each of the conduit loops, each servo control means storing temperature values desired for the controlled units and including means for sensing the actual controlled unit temperature and providing a control signal to indicate a needed correction; and
a number of proportional control valves, each disposed in a different conduit loop between the refrigeration unit and the evaporator for controlling refrigerant flow thereto in response to the control signals, to maintain the temperatures of the heat transfer fluid and the controlled units at a desired level.
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21. A system occupying a low volume, but providing adequate refrigeration capacity and temperature control for individual tools having varying temperature maintenance requirements, while permitting convenient coupling and servicing, comprising the combination of:
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a rectangular open-sided frame for containing all the interior units;
a single refrigeration unit mounted within the frame and having a refrigeration capacity substantially equal at a minimum to the maximum refrigeration demand of the tools;
a plurality of pump/motor combinations arrayed within the frame along adjacent horizontal axes, the pumps being collinear with the motors;
a plurality of heat exchanger units disposed adjacent the pump/motor combinations, the heat exchanger units being coupled in temperature control loops to different ones of the pump/motor combinations and including heater means in at least some of the loops, the heat exchanger means comprising both a first type having means for cooling the heat transfer fluid only with an unchilled liquid, and a second type for cooling the heat transfer fluid with refrigerant from the refrigeration unit, wherein the lowest temperature attainable is substantially below ambient;
the heat exchangers of the second type receiving refrigeration fluid in separate and parallel temperature control loops, each in thermal intercommunication with heat transfer fluid to be supplied to a different tool;
a plurality of control means, each associated with a separate temperature control loop for controlling the temperature of the heat transfer fluid to a different tool, and providing the heat exchangers of the first type with an on/off binary-controlled flow of unchilled liquid, and providing heat exchangers of the second type with a proportional flow of expanded refrigerant; and
wherein the system further comprises a pressurized reservoir for heat transfer fluid and a pressurized reservoir for refrigeration fluid feeding the parallel control loops.
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22. The method of controllably regulating the separate temperatures of at least a number of the tools in a cluster tool comprising the steps of:
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passing pressurized heat transfer fluid in individual thermal exchange relation with different separate tools;
providing a single flow of refrigerant having refrigeration capacity adequate for the concurrent refrigeration maximum of at least some of those of the tools that are to be refrigerated below ambient level;
branching the refrigerant into separate heat exchange paths in thermal interchange relation with the heat transfer fluid, one path for each control loop associated with a tool that is to be lowered below ambient temperature;
providing separate control signals representative of the current temperature level desired for the different individual tools; and
individually controlling the temperatures of the heat transfer fluids in each of the separate control loops by varying the temperatures of the refrigerants in those branches to maintain the temperatures of the tools at their desired levels. - View Dependent Claims (23, 24, 25, 26, 29, 30, 31, 32, 33, 34, 35, 36, 38, 39)
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27. The method for controllably regulating the separate temperatures of different devices with a single temperature control unit comprising the steps of:
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passing pressurized heat transfer fluid in individual thermal exchange relation with different ones of the devices;
providing a single flow of subcooled, pressurized refrigerant adequate in refrigeration capacity to meet the demands for refrigeration of the different devices;
branching the subcooled refrigerant into separate heat exchange paths for the different devices; and
individually controlling the temperatures of the different devices by evaporating the refrigerant in the separate branches at different flow rates.
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28. A compact unit having a low footprint area, for controlling, with heat interchange fluids, the temperature of each of a number of different fabrication tools which may be arranged in a cluster, comprising:
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an open frame delineating an open interior volume of rectangular form and including a horizontal base of the requisite small footprint area and open sides, one of which is accessible to the tools;
an array of heat interchange fluid pumps mounted in the frame, each disposed about a different horizontal axis in an upper region of the frame, the pumps including inlets and outlets accessible at a first open side of the frame for individual coupling to the tools;
a number of heat exchangers disposed below the pump array within the frame;
a common heat transfer fluid tank mounted within the frame adjacent the array of pumps, and coupled thereto;
a number of temperature control conduits coupling the inlets and outlets of the different pumps to different heat exchangers in separate control loops; and
a single refrigeration unit mounted within the frame adjacent the array and including a compressor having adequate refrigeration capacity for the total refrigeration demand of the different tools, and the compressor being coupled to supply chilled refrigerant to at least some of the heat exchangers.
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37. The method of removing pressurized thermal control fluid from a selected semiconductor fabrication tool connected by input and output lines to a temperature control unit including a pressurized thermal control fluid source comprising the steps of:
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closing off the lines at the temperature control unit;
feeding a gas under pressure into one line in the region of a low point in the lines while coupling a region of the other lines adjacent the tool to the fluid source to drive thermal control fluid from the low point in the first line, the tool and, from a part of the second line into the pressurized thermal control fluid source;
opening the said one line at the temperature control unit;
feeding the gas under pressure into the said other line adjacent the tool to drive the thermal control fluid remaining in the said other line and tool back into the source; and
closing off both lines.
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40. The method of isolating a tool in a cluster tool from a source of heat transfer fluid conducted to and from a control channel by a pair of disconnectable lines, at least one of which is below the tool, comprising the steps of:
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providing a source of pressurized heat transfer fluid to the lines;
first purging the heat transfer fluid from a part of the disconnectable lines by driving the fluid under gas pressure from a low region of the lines through the tool and toward the source from a point near the tool;
again purging the heat transfer fluid from a part of the disconnectable lines by driving the fluid under gas pressure from the point near the tool and through a part of the control channel toward the source;
disconnecting the tool from the control channel for appropriate servicing or replacement;
reconnecting the tool to the control channel; and
refilling the control loop from the pressurized reservoir. - View Dependent Claims (41)
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42. In a system that provides heat transfer fluid to a number of tools in separate loops, to provide temperature control of the loops, a subsystem for enabling individual tools to be cleared of heat transfer fluid comprising:
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a single pressurized reservoir for the heat transfer fluid;
a number of control loops for individual control systems for the different tools, the control loops including return ports and outlet ports, each having an associated flow control valve;
a number of tool conduit systems, each for a different tool, and each including return and input lines connectable to the return and outlet couplings respectively for the different tools, each conduit system including a low point below the tool;
a number of purge gas inputs, each coupled to a different control loop conduit adjacent at least the low point;
therein;
a source of pressurized gas available to be coupled to the purge inputs to the control loops; and
at least one heat transfer fluid line, adapted to be coupled between the source of pressurized heat transfer fluid and a chosen one of the control loops, at the low point, whereby by coupling the source of purge gas to a purge gas input in a control loop, heat transfer fluid is driven out of the tool loop toward the pressurized reservoir. - View Dependent Claims (43)
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44. A temperature control unit configuration for providing multiple temperature controlled fluid lines for different tools in a cluster, each tool to be independently temperature controlled, while the temperature control unit occupies minimal floor area and allows independent servicing of the tools, comprising:
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a frame having the desired low floor area, the frame having at least one substantially vertical and open access side;
a plurality of pump/motor combinations arrayed within and coupled to the frame within a first interior volume of the frame, the pump/motor combinations being disposed about separate horizontal axes and arrayed together adjacent the access side;
a plurality of return line couplings, each disposed on the access side of the frame adjacent the first interior volume and coupled to different ones of the pumps for intercoupling to the different tools;
a plurality of outlet line couplings disposed in a vertical plane adjacent the access side of the frame and adjacent the first interior volume, the outlet line couplings being coupled to different ones of the pumps and available for intercoupling to the different tools;
a plurality of temperature control means disposed within the frame and below the first interior volume, the temperature control means including heat exchanger means;
a single refrigeration unit including compressor and condenser means disposed within the frame, adjacent and to one side of the first interior volume;
a refrigeration unit disposed within the frame adjacent the opposite side of the frame from the first interior volume;
a plurality of conduits coupling refrigerant from the refrigeration unit to those of the heat exchanger means requiring refrigeration; and
a source of pressurized heat transfer fluid within the frame above the refrigeration unit and coupled to each of the heat exchanger means. - View Dependent Claims (45, 46, 48, 49, 50)
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47. A compact system for delivering thermal transfer fluid in different channels at adjustable temperature levels to control the temperatures of different tools, comprising:
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a frame structure having a low area base and frame elements extending vertically therefrom to provide containment for the components of the system, the frame structure having at least one vertical, open, access side;
a number of adjacent pump/motor combinations disposed along parallel rotational axes in an array in an upper region of the frame structure, the pump/motor combination having an inlet and outlet ports disposed adjacent the access side;
a refrigeration unit including a compressor mounted in a lower region of the frame structure, the refrigeration unit providing a pressurized, low temperature refrigerant in liquid phase;
at least one evaporation/heat exchanger unit coupled to one of the pump/motor combinations and receiving both pressurized refrigerant and thermal transfer fluid in an individual channel, the at least one evaporator/heat exchanger unit being disposed between the pump/motor array and the refrigeration unit; and
at least one controllable thermal expansion valve disposed between the refrigeration unit and the at least one evaporator/heat exchanger unit for regulating the temperatures of the thermal transfer fluid thereof.
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51. A temperature control unit for coupling to a cluster of semiconductor fabrication tools to control the temperature of each tool separately in accordance with an individual program for that tool, comprising:
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a number of temperature control channels, each including operative elements physically intermingled with elements from other channels, and each having a heat exchange loop coupled to a different fabrication tool, the channels each including a common coolant and a separate pressurizing pump for the coolant;
a refrigeration system having a plurality of operative elements disposed in distributed relation among the temperature control channels, and including a refrigerant distribution and return system;
a heat exchange system coupling the refrigerant distribution and return system to at least one of the heat exchange loops, the heat exchange system also being distributed among the elements of the temperature control channels; and
the unit having all the operative elements thereof disposed within a volume of less than about two cubic feet per channel. - View Dependent Claims (52, 53, 54)
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55. For separately controlling the temperature of a number of processing tools with a heat exchange fluid, a method comprising the steps of:
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providing a flow of pressurized low temperature refrigerant having sufficient refrigeration capacity for the total concurrent needs of the processing tools;
flowing the refrigerant into different branches, one for each tool to be refrigerated;
controlling the refrigerants flows in the different branches in accordance with desired temperatures by lowering the pressure of the refrigerant in each branch to a selected individual level; and
circulating the heat exchange fluid in separate loops in thermal relation to the tools and to the controlled refrigerant flows. - View Dependent Claims (56)
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Specification