Methods and apparatus for coupling semiconductor device manufacturing equipment to the facilities of a manufacturing location
In a first aspect, an apparatus is provided for coupling a semiconductor device manufacturing tool to facilities. The apparatus includes (1) a docking station adapted to mount to a raised floor and having a thickness approximately equal to the raised floor; (2) a plurality of tool point of connection (POC) locations disposed on a top surface of the docking station, each tool POC location being adapted to be connected to a POC of a semiconductor device manufacturing tool; and (3) a plurality of facilities POC locations disposed on a bottom surface of the docking station. Each facilities POC location is adapted to be connected to a POC of a facility. Numerous other aspects are provided.
The present application claims priority from U.S. Provisional Patent Application Ser. No. 60/720,958, filed Sep. 27, 2005, which is hereby incorporated by reference herein in its entirety.
FIELD OF THE INVENTIONThe present invention relates generally to semiconductor device manufacturing, and more particularly to methods and apparatus for coupling semiconductor device manufacturing equipment to the facilities of a manufacturing location.
BACKGROUND OF THE INVENTIONThe installation of equipment into a semiconductor device manufacturing location (e.g., building, structure, manufacturing plant and the like) may be time and labor intensive. The time and labor required to install the equipment may be significantly impacted by the time and labor required to attach or couple the equipment to the manufacturing location's facilities. The facilities may include services such as air, water, process gas, vacuum, electricity and the like. The equipment may be connected to the services by coupling the equipment's point(s) of connections (POCs) with the facilities' POCs. Because semiconductor device manufacturing locations may have space constraints, access to the facilities' POCs may be constricted. Thus, there is a need for methods and apparatus for efficiently coupling semiconductor device manufacturing equipment to the facilities of a manufacturing location.
SUMMARY OF THE INVENTIONIn a first aspect of the invention, an apparatus is provided for coupling a semiconductor device manufacturing tool to facilities. The apparatus includes (1) a docking station adapted to mount to a raised floor and having a thickness approximately equal to the raised floor; (2) a plurality of tool point of connection (POC) locations disposed on a top surface of the docking station, each tool POC location being adapted to be connected to a POC of a semiconductor device manufacturing tool; and (3) a plurality of facilities POC locations disposed on a bottom surface of the docking station. Each facilities POC location is adapted to be connected to a POC of a facility.
In a second aspect of the invention, a method is provided for pre-facilitating a semiconductor device manufacturing tool. The method includes the step of providing a docking station having (1) a thickness approximately equal to a raised floor; (2) a plurality of tool point of connection (POC) locations disposed on a top surface of the docking station, each tool POC location being adapted to be connected to a POC of a semiconductor device manufacturing tool; and (3) a plurality of facilities POC locations disposed on a bottom surface of the docking station. Each facilities POC location is adapted to be connected to a POC of a facility. The method further includes the steps of (1) mounting the docking station to the raised floor; and (2) connecting the facilities POC locations to POCs of a facility.
In a third aspect of the invention, a method is provided for manufacturing a docking station. The method includes the steps of (1) constructing a frame having a thickness approximately equal to a raised floor; (2) installing a plurality of tool point of connection (POC) locations on a top surface of the frame, each tool POC location being adapted to be connected to a POC of a semiconductor device manufacturing tool; and (3) installing a plurality of facilities POC locations on a bottom surface of the frame. Each facilities POC location is adapted to be connected to a POC of a facility.
In a fourth aspect of the invention, a raised floor system is provided. The raised floor system includes a docking station having (1) a thickness approximately equal to a raised floor, (2) a plurality of tool point of connection (POC) locations disposed on a top surface of the docking station, each tool POC location being adapted to be connected to a POC of a semiconductor device manufacturing tool; and (3) a plurality of facilities POC locations disposed on a bottom surface of the docking station. Each facilities POC location is adapted to be connected to a POC of a facility. The raised floor system also includes a raised floor adapted to support the docking station.
In a fifth aspect of the invention, a semiconductor device manufacturing system is provided. The semiconductor device manufacturing system includes a docking station having (1) a thickness approximately equal to a raised floor; (2) a plurality of tool point of connection (POC) locations disposed on a top surface of the docking station, each tool POC location being adapted to be connected to a POC of a semiconductor device manufacturing tool, and (3) a plurality of facilities POC locations disposed on a bottom surface of the docking station. Each facilities POC location is adapted to be connected to a POC of a facility. The semiconductor device manufacturing system also includes a semiconductor device manufacturing tool including a plurality of tool POCs adapted to be coupled to the plurality of tool point of connection (POC) locations. Numerous other aspects are provided.
Other features and aspects of the present invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention provides a docking station adapted to couple equipment (e.g., semiconductor device processing equipment and the like) to facilities of a manufacturing location (e.g., at point(s) of connections (POCs) for the facilities). The docking station may be employed to pre-facilitize (or “facilitize”) a location at which semiconductor device processing equipment is to be installed (e.g., by pre-plumbing, pre-wiring, etc., any required facilities lines and/or other services at and/or to the docking station before arrival of the semiconductor device processing equipment so that connection of facilities to the semiconductor device processing equipment need only be made at the docking station location when the semiconductor device processing equipment is installed). Time required to install the semiconductor device processing equipment thereby may be greatly reduced.
In an embodiment of the present invention, the docking station may be a sheet of material (e.g., steel, aluminum, plastic and the like) with features that may couple to the facilities' POCs and/or a floor of the manufacturing location. For example, the floor may be a raised metal floor (RMF) or similar floor with space between the floor and an underlying supporting structure (e.g., ground, structural I-beams, etc.). The docking station may be disposed so as to not interfere with the floor's support structure, or the facility lines, etc., that may be disposed between the floor and the underlying supporting structure. In addition, the docking station may be disposed underneath the equipment such that the area utilized (e.g., footprint and the like) by the equipment is not increased due to the employment of the docking station.
The docking station may be integral with or separate from the equipment. A separate docking station may allow the docking station to be coupled to the facilities' POCs prior to delivery and/or installation of the equipment. Thereafter, when the equipment is installed in the semiconductor device manufacturing location, the equipment may be coupled to the facilities' POCs and/or docking station. This may allow the installation and/or startup time of the equipment to be significantly reduced. These and other aspects of the invention are discussed below.
With reference to
In the embodiment of
The docking station 102 may include holes and/or cutouts of different sizes and/or shapes. For example, the gas lines 108, the vacuum lines 110 and/or the water lines 112 may pass through holes and/or adapters of various sizes/and or shapes. In a further example, the gas lines 108, the vacuum lines 110, and/or the water lines 112 may be coupled to adapters that couple to the semiconductor processing equipment 106.
With reference to
The docking station 200 of
In some embodiments, the height T2 of the space below the docking station 200 may be approximately equal to the height of the space below the raised floor 402 as depicted in
In at least one embodiment of the invention, the connection and/or pass-through locations of the docking station 200 may be divided and/or logically grouped or arranged. For example,
With reference to
Embodiments of the inventive docking station described herein provide for fewer possible connection interferences below a raised floor, provide more room for connections and/or easier access to connections (e.g., such as water or other connections), allow for multiple AC conduit approaches and/or provide about the same or less bends to facility lines (when compared to a conventional connection box).
The foregoing description discloses only exemplary embodiments of the invention. Modifications of the above disclosed apparatus and methods which fall within the scope of the invention will be readily apparent to those of ordinary skill in the art. For instance, the docking station may be made of PVC material and/or oriented at an angle towards the tool. In general, the docking station may be made of any of a variety of structural materials, including, for example, cold-rolled steel, stainless steel, aluminum sheet metal, etc. Overall dimensions of the docking station may vary depending on the type of tool to be facilitized, but a compact structure is preferable in some embodiments. For a full complement of facilities, including gas, water, electrical, vacuum, CDA, and ventilation connections, a docking station may be approximately 6 inches long by 2 inches wide by 3 inches deep, although other dimensions may be used.
In some embodiments, the docking station 200 may have a similar length and width to that of a conventional connection box, but a significantly reduced height/thickness (e.g., about the same thickness as a floor tile of a raised floor to which the docking station 200 is to couple). The docking station 200 may include connection fittings such as KF-50, ½″ VCR, DNet, etc., connections. Any suitable number, size and/or type of connection fittings may be used. Toxic boots or other secondary containment devices may be coupled to and/or used with the docking station 200 (e.g., for removing toxic exhaust and/or other waste from a tool and/or processing chamber).
In at least one embodiment of the invention, an apparatus is provided for coupling a semiconductor device manufacturing tool to facilities. The apparatus includes (1) a docking station adapted to mount to a raised floor and having a thickness approximately equal to the raised floor; (2) a plurality of tool point of connection (POC) locations disposed on a top surface of the docking station, each tool POC location being adapted to be connected to a POC of a semiconductor device manufacturing tool; and (3) a plurality of facilities POC locations disposed on a bottom surface of the docking station. Each facilities POC location is adapted to be connected to a POC of a facility.
In one or more embodiments of the invention, a method is provided for pre-facilitating a semiconductor device manufacturing tool. The method includes the step of providing a docking station having (1) a thickness approximately equal to a raised floor; (2) a plurality of tool point of connection (POC) locations disposed on a top surface of the docking station, each tool POC location being adapted to be connected to a POC of a semiconductor device manufacturing tool; and (3) a plurality of facilities POC locations disposed on a bottom surface of the docking station. Each facilities POC location is adapted to be connected to a POC of a facility. The method further includes the steps of (1) mounting the docking station to the raised floor; and (2) connecting the facilities POC locations to POCs of a facility.
In some embodiments of the invention, a method is provided for manufacturing a docking station. The method includes the steps of (1) constructing a frame having a thickness approximately equal to a raised floor; (2) installing a plurality of tool point of connection (POC) locations on a top surface of the frame, each tool POC location being adapted to be connected to a POC of a semiconductor device manufacturing tool; and (3) installing a plurality of facilities POC locations on a bottom surface of the frame. Each facilities POC location is adapted to be connected to a POC of a facility.
In certain embodiments of the invention, a raised floor system is provided. The raised floor system includes a docking station having (1) a thickness approximately equal to a raised floor, (2) a plurality of tool point of connection (POC) locations disposed on a top surface of the docking station, each tool POC location being adapted to be connected to a POC of a semiconductor device manufacturing tool; and (3) a plurality of facilities POC locations disposed on a bottom surface of the docking station. Each facilities POC location is adapted to be connected to a POC of a facility. The raised floor system also includes a raised floor adapted to support the docking station.
In one or more embodiments of the invention, a semiconductor device manufacturing system is provided. The semiconductor device manufacturing system includes a docking station having (1) a thickness approximately equal to a raised floor; (2) a plurality of tool point of connection (POC) locations disposed on a top surface of the docking station, each tool POC location being adapted to be connected to a POC of a semiconductor device manufacturing tool, and (3) a plurality of facilities POC locations disposed on a bottom surface of the docking station. Each facilities POC location is adapted to be connected to a POC of a facility. The semiconductor device manufacturing system also includes a semiconductor device manufacturing tool including a plurality of tool POCs adapted to be coupled to the plurality of tool point of connection (POC) locations.
Accordingly, while the present invention has been disclosed in connection with exemplary embodiments thereof, it should be understood that other embodiments may fall within the spirit and scope of the invention, as defined by the following claims.
Claims
1. An apparatus for coupling a semiconductor device manufacturing tool to facilities, the apparatus comprising:
- a docking station adapted to mount to a raised floor and having a thickness approximately equal to the raised floor;
- a plurality of tool point of connection (POC) locations disposed on a top surface of the docking station, wherein each tool POC location is adapted to be connected to a POC of a semiconductor device manufacturing tool; and
- a plurality of facilities POC locations disposed on a bottom surface of the docking station, wherein each facilities POC location is adapted to be connected to a POC of a facility.
2. The apparatus of claim 1, wherein the docking station is further adapted to mount to a raised floor in place of a standard raised floor tile.
3. The apparatus of claim 1, wherein the thickness of the docking station is approximately equal to a standard raised floor tile.
4. The apparatus of claim 1, wherein the bottom surface of the docking station is approximately co-planar with a bottom surface of the raised floor.
5. The apparatus of claim 1, wherein a height of a space below the raised floor is approximately the same as a height of a space below the docking station.
6. The apparatus of claim 1, wherein the facilities POC locations are disposed so that attaching the facility POCs does not interfere with support structures of the raised floor.
7. The apparatus of claim 1, wherein the thickness of the docking station is such that attaching the facility POCs does not interfere with support structures of the raised floor.
8. The apparatus of claim 1, wherein the top surface of the docking station is below a top surface of the raised floor.
9. A method of pre-facilitating a semiconductor device manufacturing tool comprising:
- providing a docking station having: a thickness approximately equal to a raised floor, a plurality of tool point of connection (POC) locations disposed on a top surface of the docking station wherein each tool POC location is adapted to be connected to a POC of a semiconductor device manufacturing tool, and a plurality of facilities POC locations disposed on a bottom surface of the docking station, wherein each facilities POC location is adapted to be connected to a POC of a facility;
- mounting the docking station to the raised floor; and
- connecting the facilities POC locations to POCs of a facility.
10. The method of claim 9, wherein providing a docking station includes providing a docking station further adapted to mount to a raised floor in place of a standard raised floor tile.
11. The method of claim 9, wherein providing a docking station includes providing a docking station wherein the thickness of the docking station is approximately equal to a standard raised floor tile.
12. The method of claim 9, wherein providing a docking station includes providing a docking station wherein the bottom surface of the docking station is approximately co-planar with a bottom surface of the raised floor.
13. The method of claim 9, wherein providing a docking station includes providing a docking station wherein a height of a space below the raised floor is approximately the same as a height of a space below the docking station.
14. The method of claim 9, wherein providing a docking station includes providing a docking station wherein the facilities POC locations are disposed so that attaching the facility POCs does not interfere with support structures of the raised floor.
15. The method of claim 9, wherein providing a docking station includes providing a docking station wherein the thickness of the docking station is such that attaching the facility POCs does not interfere with support structures of the raised floor.
16. The method of claim 9, wherein providing a docking station includes providing a docking station wherein the top surface of the docking station is below a top surface of the raised floor.
17. A method of manufacturing a docking station comprising:
- constructing a frame having a thickness approximately equal to a raised floor;
- installing a plurality of tool point of connection (POC) locations on a top surface of the frame wherein each tool POC location is adapted to be connected to a POC of a semiconductor device manufacturing tool; and
- installing a plurality of facilities POC locations on a bottom surface of the frame, wherein each facilities POC location is adapted to be connected to a POC of a facility.
18. The method of claim 17, wherein constructing a frame includes constructing a frame adapted to mount to a raised floor in place of a standard raised floor tile.
19. The method of claim 17, wherein constructing a frame includes constructing a frame wherein the thickness of the frame is approximately equal to a standard raised floor tile.
20. The method of claim 17, wherein constructing a frame includes constructing a frame wherein the bottom surface of the frame is approximately co-planar with a bottom surface of the raised floor.
21. The method of claim 17, wherein constructing a frame includes constructing a frame wherein a height of a space below the raised floor is approximately the same as a height of a space below the frame.
22. The method of claim 17, wherein constructing a frame includes constructing a frame wherein the facilities POC locations are disposed so that attaching the facility POCs does not interfere with support structures of the raised floor.
23. The method of claim 17, wherein constructing a frame includes constructing a frame wherein the thickness of the frame is such that attaching the facility POCs does not interfere with support structures of the raised floor.
24. The method of claim 17, wherein constructing a frame includes constructing a frame wherein the top surface of the frame is below a top surface of the raised floor.
25. A raised floor system comprising:
- a docking station having: a thickness approximately equal to a raised floor, a plurality of tool point of connection (POC) locations disposed on a top surface of the docking station wherein each tool POC location is adapted to be connected to a POC of a semiconductor device manufacturing tool, and a plurality of facilities POC locations disposed on a bottom surface of the docking station, wherein each facilities POC location is adapted to be connected to a POC of a facility; and
- a raised floor adapted to support the docking station.
26. The system of claim 25, wherein the docking station is further adapted to mount to the raised floor in place of a standard raised floor tile/panel.
27. The system of claim 25, wherein the thickness of the docking station is approximately equal to a standard raised floor tile/panel.
28. The system of claim 25, wherein the bottom surface of the docking station is approximately co-planar with a bottom surface of the raised floor.
29. The system of claim 25, wherein a height of a space below the raised floor is approximately the same as a height of a space below the docking station.
30. The system of claim 25, wherein the facilities POC locations are disposed so that attaching the facility POCs does not interfere with support structures of the raised floor.
31. The system of claim 25, wherein the thickness of the docking station is such that attaching the facility POCs does not interfere with support structures of the raised floor.
32. The system of claim 25, wherein the top surface of the docking station is below a top surface of the raised floor.
33. A semiconductor device manufacturing system comprising:
- a docking station having: a thickness approximately equal to a raised floor, a plurality of tool point of connection (POC) locations disposed on a top surface of the docking station wherein each tool POC location is adapted to be connected to a POC of a semiconductor device manufacturing tool, and a plurality of facilities POC locations disposed on a bottom surface of the docking station, wherein each facilities POC location is adapted to be connected to a POC of a facility; and
- a semiconductor device manufacturing tool including a plurality of tool POCs adapted to be coupled to the plurality of tool point of connection (POC) locations.
34. The system of claim 33, wherein the docking station is further adapted to mount to the raised floor in place of a standard raised floor tile/panel.
35. The system of claim 33, wherein the thickness of the docking station is approximately equal to a standard raised floor tile/panel.
36. The system of claim 33, wherein the bottom surface of the docking station is approximately co-planar with a bottom surface of the raised floor.
37. The system of claim 33, wherein a height of a space below the raised floor is approximately the same as a height of a space below the docking station.
38. The system of claim 33, wherein the facilities POC locations are disposed so that attaching the facility POCs does not interfere with support structures of the raised floor.
39. The system of claim 33, wherein the thickness of the docking station is such that attaching the facility POCs does not interfere with support structures of the raised floor.
40. The system of claim 33, wherein the top surface of the docking station is below a top surface of the raised floor.
Type: Application
Filed: Sep 26, 2006
Publication Date: Apr 12, 2007
Inventors: Nicholas de Vries (Alameda, CA), Aaron Webb (Austin, TX)
Application Number: 11/527,771
International Classification: B24B 7/00 (20060101);