The present application relates to material processing technologies, and more specifically to low cost and high throughput processing apparatus.
Material processing is widely used in photovoltaic cells and panels, window glass coating, flat panel display manufacturing, coating on flexible substrates, hard disk coating, industrial surface coating, semiconductor wafer processing, and other applications.
High volume production systems used for these applications typically comprise of interconnected box-shaped chambers that accept one or two rows of substrates. The foot print of such system is large due to the need to have multiple load locks and buffer chambers. The process sequence is determined by the hardware configuration and difficult to change in day to day operation and during research and development.
Another high volume production system used in volume processing applications is cluster tool with individual process chambers attached to a central transfer chamber with robot arms. This kind of system allow various processes and process sequence to be run in the same system, but the cost is higher due to the expense of additional large central chamber. A single robot serves all process chambers in a cluster tool, limiting the throughput of such system.
There is therefore a need for high throughput processing systems that is simpler, offers more process flexibility and has lower equipment cost.
The present application discloses a high throughput processing apparatus that reduces equipment cost; increases number of the substrates in processing chamber, enable multiple processes and process sequences to be carried out in the same system, and provide high throughput substrate processing.
In present invention, each processing chamber has its own substrate handling arm that can pick up one or more substrates or substrate carrier from a transfer chamber, load the substrates or substrate carrier into the process chamber or scan the substrates relative to one or more processing sources inside the process chamber, and place the substrates or substrate carrier back to the transfer chamber. The handling arm can hold the substrate by gravity in case the substrate is held horizontally, by electrostatic force, or by mechanical engagement to a substrate carrier, as shown in
One or two process chambers can be attached to each transfer chamber, via optional gate valves, as shown in sectional view
This system has the advantage of being scalable from one to many process chambers. The substrate handling arm can be simple and inexpensive. One axis of motion is required, if the cassette can move relative to the handling arm to load/unload the substrates. A secondary motion can be added to the handling arm for small additional cost, where the second motion engages the substrate or substrate carrier to load or unload the substrates to or from the handling arm. The substrate handling arm also serves as an optional scanning mechanism to improve the processing uniformity. There can be optional heater inside the process chamber.
The cassette in the transfer chamber can be mounted on wheels and mounted on one or more rail tracks, as shown in
A plurality of substrates and substrate carriers can be mounted in a cassette, as shown in
During operation, a cassette is mounted to the cassette handling arm inside a load lock, the load lock is pumped down, the gate valve between load lock and transfer chamber is open, the cassette is inserted and the wheels ride on the one or more guide rails until the cassette is stopped by a extruded chain link on the chain, the chain and cassette handling arm moves the cassette together until a second extruded chain link catches the cassette. The cassette handling arm is then retracted back to the load lock and the gate valve between transfer chamber and load lock is closed. After the substrates are processed in the process chamber, the cassette is engaged to the cassette handling arm again and the chain moves the cassette until one of the extruded chain link rotates past the corresponding sprocket and out of cassette movement path. The cassette is moved out to the load lock and taken out after the load lock is vented. The procedure repeats.
Once the cassette is inside the transfer chamber, it moves so that the substrate handling arm from one of the process chamber can be inserted into the substrate carrier. The cassette just moves slightly so that the substrate handling arm can engage a substrate carrier through pins and magnetic force. The substrate handling arm retracts with the substrate carrier and carries out processing. After processing, the substrate carrier is inserted back to an empty slot in the cassette and disengages with the substrate handling arm with slight movement of the cassette.
The substrate carriers are confined to a plane parallel to the substrate handling arm movement by slots or wheels on the cassette, as shown in
The substrate carrier can sit on ramps with low friction coefficient so that the position accuracy of the substrate handling arm is not critical. To prevent the substrate carrier movement in the plane of the substrate handling arm movement, the substrate carrier can be confined by magnets mounted on the cassette and yet can break the confinement by a larger external force such as the substrate handling arm. Other means of confining the substrate carrier includes hard stops or other mechanism.
In case the substrate carrier is held in a tilted or vertical position, a holding force such as magnetic force or electrostatic force is applied.
In some embodiments, the invention describes a processing system, that comprises a first process chamber, wherein the first process chamber comprises a first deposition or processing source, a first deposition or processing mechanism, and a first substrate moving mechanism, wherein the first deposition or processing source is configured to deposit material on one or more substrates via the first deposition mechanism or process one or more substrates, wherein the first substrate moving mechanism is configured to hold the one or more substrates and move the one or more substrates in and out of the first process chamber; a transfer chamber that couples to the first process chamber, wherein the transfer chamber contains a cassette that is configured to hold one or more substrates and another substrate moving mechanism, wherein a first transfer mechanism is configured to move a substrate to or from the first process chamber to the transfer chamber, wherein the another substrate moving mechanism is configured to move the cassette relative to the first substrate moving mechanism to engage or disengage the substrate from the first substrate moving mechanism, and move the cassette in and out of the transfer chamber. In some embodiments, the system further comprises multiple process chambers and multiple transfer chambers coupled to the multiple process chambers.
In some embodiments, the processing system has the substrate that is configured to hold a vertical position.
In some embodiments, the processing system contains two substrates that are configured to be held in a substrate carrier via a holding mechanism.
In some embodiments, the processing system has a holding mechanism that is magnetic force.
In some embodiments, the processing system has a chain that is used to move the cassette, wherein the chain has two catches and each catch of the two catches can be rotated out of the way for the cassette to move out of the transfer chamber.
In some embodiments, the processing system contains a substrate carrier that is configured to be confined by one or more magnets mounted on the cassette and paramagnetic materials on the substrate carriers, and are configured to break the confinement by a larger external force.
In some embodiments, the processing system also contains a second process chamber couples to the transfer chamber, wherein a second transfer mechanism is configured to move the one or more substrates from the transfer chamber to the second process chamber, wherein the second process chamber comprises a second deposition or processing source, a second deposition or processing mechanism, and a second substrate moving mechanism, wherein the second deposition source is configured to deposit material on a substrate via the second deposition mechanism or process one or more substrates, wherein the second substrate moving mechanism is configured to hold the one or more substrates and move the one or more substrates in and out of the second process chamber.
In some embodiments, the transfer chamber couples to the first process chamber via a first gate valve, wherein the second process chamber couples to the transfer chamber via a second gate valve.
In some embodiments, the first process chamber, the transfer chamber and the second process chamber are linearly aligned.
In some embodiments, the invention describes a processing system that is comprising: a first process chamber, wherein the first process chamber comprises a first deposition or processing source, a first deposition or processing mechanism, and a first substrate moving mechanism, wherein the first deposition source is configured to deposit material on one or more substrates via the first deposition mechanism or the first processing source is configured to process one or more substrates, wherein the first substrate moving mechanism is configured to hold one or more substrates and move the one or more substrates in and out of the first process chamber; and a transfer chamber that couples to the first process chamber, wherein the transfer chamber contains a cassette that is configured to hold one or more substrates and another substrate moving mechanism, wherein a first transfer mechanism is configured to move a substrate to or from the first process chamber to the transfer chamber, wherein the another substrate moving mechanism is configured to move the cassette relative to the first substrate moving mechanism to engage or disengage the substrate from the first substrate moving mechanism, and move the cassette in and out of the transfer chamber; and one or two load locks that are connected to the transfer chamber via one or two gate valves, wherein the one or two load locks are configured to enable the cassette of substrates to be loaded in the first load lock of the one or two load locks, transferred between the first load lock to the transfer chamber, waiting for the substrates to be processed and returned to the cassette, and unloaded to the first load lock or a different load lock.
In some embodiments, the system further comprises: multiple process chambers; and multiple transfer chambers coupled to the multiple process chambers via multiple gate valves.
In some embodiments, the substrate is configured to hold a vertical position.
In some embodiments, two substrates are configured to be held in a substrate carrier via a holding mechanism.
In some embodiments, a chain is used to move the cassette, wherein the chain has two catches and each catch of the two catches can be rotated out of the way for the cassette to move out of the transfer chamber.
In some embodiments, the substrate carrier is configured to be confined by one or more magnets mounted on the cassette and paramagnetic materials on the substrate carriers, and are configured to break the confinement by a larger external force.
In some embodiments, the system is further comprising: a second process chamber that couples to the transfer chamber, wherein a second transfer mechanism configured to move the one or more substrates from the transfer chamber to the second process chamber, wherein the second process chamber comprises a second deposition or processing source, a second deposition or processing mechanism, and a second substrate moving mechanism, wherein the second deposition source is configured to deposit material on a substrate via the second deposition mechanism or the second processing source is configured to process one or more substrates, wherein the second substrate moving mechanism is configured to move the one or more substrates in and out of the second process chamber.
In some embodiments, the transfer chamber couples to the first process chamber via a first gate valve, wherein the second process chamber couples to the transfer chamber via a second gate valve.
In some embodiments, the first process chamber, the transfer chamber and the second process chamber are linearly aligned.
Once the cassette is inside the transfer chamber, it moves so that the substrate handling arm from one of the process chamber can be inserted into the substrate carrier. The cassette just moves slightly so that the substrate handling arm can engage a substrate carrier through pins and magnetic force. The substrate handling arm retracts with the substrate carrier and carries out processing. After processing, the substrate carrier is inserted back to an empty slot in the cassette and disengages with the substrate handling arm with slight movement of the cassette.
The substrate carrier can sit on ramps 607 with low friction coefficient so that the position accuracy of the substrate handling arm is not critical. To prevent the substrate carrier movement in the plane of the substrate handling arm movement, the substrate carrier can be confined by magnets 608 mounted on the cassette and paramagnetic materials on substrate carriers 609, and yet can break the confinement by a larger external force such as the substrate handling arm. Other means of confining the substrate carrier includes hard stops or other mechanism.
This application is a non-provisional utility patent application that claims the benefit of U.S. Provisional Patent Application No. 62/261,865, which was filed on Dec. 2, 2015, all of which are incorporated by reference herein in its entirety.