Wafer holding assembly and wafer processing apparatus having said assembly

A wafer holder for a semiconductor processing apparatus comprising:

• a rigid annular housing having a central axis;
• a wafer mounting ring having a back side having an inner edge and a front side and an annular wafer engaging surface on the inner edge of the back side thereof, the ring being centered on the axis and resiliently mounted on its back side to the housing at a plurality of six points approximately equally spaced around the housing to translate toward and away from the housing without making sliding contact with the housing;
• a set of three approximately equally spaced leaf springs and a set of three approximately equally spaced coil springs, one spring being mounted at each of the six points, to bias the ring toward the housing;
• a set of three latch assemblies each pivotally mounted to the back side of the mounting ring and equally spaced around the axis, each latch assembly having a mounting post fixed and perpendicular to the back side of the mounting ring and having a spring loaded ball bearing joint biasing the latch assembly toward the mounting ring and rotatably connecting the latch assembly to the mounting ring for rotation about the mounting post, each mounting post being releasable for removing the latch assembly as a unit from the mounting ring, each latch assembly being rotatable through approximately 90.degree. between a latched position and an unlatched position;
• each latch assembly having:
• a non-metallic latch body having a plurality of oversize actuator pin receiving slots therein equally spaced around the mounting post,
• a non-metallic front roller rotatable on the body about an axis perpendicular to and intersecting the mounting post, the front roller having:
• a gripping periphery which lies adjacent the wafer engaging surface of the mounting ring when the latch assembly is rotated to its latched position and having an outwardly diverging conical axial cross-section with rounded edges, and
• a rolling periphery greater than the gripping periphery and which lies adjacent a circle around the mounting post on the back side of the wafer mounting ring,
• a non-metallic rear roller rotatable on the body about the axis of the front roller perpendicular to and intersecting the mounting post, the rear roller having a rolling periphery approximately equal to the rolling periphery of the front roller and which lies adjacent the same circle around the mounting post on the back side of the wafer mounting ring, and
• a plurality of detents in the back side of the wafer mounting ring lying on said circle, including a pair of side detents on opposite sides of said mounting post to receive the rolling peripheries of the front and rear rollers when the latch assembly is in an unlatched position and a front and back detent adapted to receive the rolling peripheries of the respective front and rear rollers when the latch assembly is in a latched position, the side and rear detents having equal depths and the front detent having a greater depth such that the rolling periphery of the front roller is seated in the front detent only when the latch assembly is in a latched position with no wafer in the holder.

A semiconductor wafer processing apparatus comprising:

• a load chamber;
• a wafer holder in the chamber having:
• a rigid annular housing having a central axis and a center,
• a wafer mounting ring having a back side having an inner edge and a front side and an annular wafer engaging surface on the inner edge of the back side thereof, the ring being centered on the axis and resiliently mounted on its back side to the housing at a plurality of points around the housing so that the ring translates toward and away from the housing without making sliding contact with the housing,
• a plurality of at least three latch assemblies each pivotally mounted to the back side of the mounting ring around the axis, each latch assembly having:
• a mounting post perpendicular to the back side of the mounting ring,
• a non-metallic latch body pivotally and resiliently mounted to the mounting ring at the mounting post so as to be biased toward the mounting ring and rotatable through approximately 90.degree. between a latched position and an unlatched position, the body having a plurality of oversize actuator pin receiving recesses therein equally spaced around the mounting post,
• a non-metallic front roller rotatable on the body about an axis perpendicular to and intersecting the mounting post, the front roller having a gripping periphery which lies adjacent the wafer engaging surface of the mounting ring when the latch assembly is rotated to its latched position and a rolling periphery which lies on a circle around the mounting post on the back side of the wafer mounting ring, and
• at least one non-metallic rear roller rotatable on the body about an axis perpendicular to and intersecting the mounting post, the rear roller having a rolling periphery approximately equal to the rolling periphery of the front roller and lying on said circle;
• and
• a plurality of detents in the back side of the wafer mounting ring lying on said circle to receive the rolling peripheries of the rollers when the latch assembly is in the unlatched position an the latched position;
• a load arm having a wafer chuck thereon and relatively moveable perpendicular to a plane that is parallel to the axis in a path through the center of the housing between a rearward position on the back side of the holder outside of the vacuum chamber and a forward position at which a wafer held in the wafer chuck is in contact with the wafer mounting ring and is a spaced distance forward of the plane and at which the wafer mounting ring is spaced forward of the holder and is resiliently biased rearwardly against a wafer when the wafer is being held by the wafer chuck;
• a plurality of latch actuators supported on the load arm, one corresponding to and aligned with each of the latch assemblies, the actuators having a plurality of pins thereon configured and located so as to fit loosely into the recesses in the latch body upon movement of the load arm to its forward position being relatively moveable into and out of coupling engagement with the latches when the load arm moves respectively to its forward and rearward positions;
• and
• the actuators being rotatable, when coupled to the bodies of the latch assemblies, to rotate the latch assemblies between their latched and unlatched positions.

A wafer holder for a semiconductor processing apparatus comprising:

• a rigid annular housing having a central axis;
• a wafer mounting ring having a back side having an inner edge and a front side and an annular wafer engaging surface on the inner edge of its back side, the ring being centered on the axis and resiliently mounted on its back side to the housing at a plurality of points around the housing so that the ring translates toward and away from the housing without making sliding contact with the housing;
• pivotal latching means mounted to the back side of the mounting ring, including:
• a non-metallic latch body;
• a non-metallic front roller rotatable on the body and having a gripping periphery which lies adjacent the wafer engaging surface of the mounting ring when the latching means is rotated to a latched position and a rolling periphery in rolling contact with the back side of the wafer mounting ring, and
• at least one non-metallic rear roller rotatable on the body in rolling contact with the back side of the wafer mounting ring;
• and
• means for retaining the latching means is in its latched or an unlatched position.

A method of supporting semiconductor wafer in a processing apparatus, the method comprising the steps of:

• providing a wafer holder having a wafer mounting ring resiliently mounted thereon in the vacuum chamber;
• providing a plurality of latches rotatably mounted to the wafer mounting ring;
• moving a wafer on a transfer arm against the mounting ring;
• then rotating the latches with actuators on the transfer arm to bring a first rolling surface on the latches into rolling contact with the wafer and to grip the wafer between the rollers and the mounting ring;
• then releasing the wafer from the transfer arm and to the holder;
• and
• the latch rotating step including the step of maintaining rolling contact between a second rolling surface of the latches and the mounting ring while simultaneously moving each of the latches from a stable unlatched position on the ring to a stable latched position on the ring.

A latch assembly for a wafer holder having a wafer mounting ring with an annular wafer engaging surface on a inner edge thereof, the assembly comprising:

• a non-metallic latch body configured to pivotally mount to the wafer holder at a mounting axis perpendicular thereto;
• a mounting post centered on the mounting axis and configured to removably pivotally connect the latch body assembly to the wafer holder;
• a non-metallic front roller rotatable on the body and having a gripping periphery positioned to clamp a wafer against the wafer engaging surface of the mounting ring when the latching assembly is rotated to a latched position and having a rolling periphery situated between the gripping periphery and the mounting axis and positioned to lie in rolling contact with the wafer holder when the latch body is connected thereto by the mounting post;
• at least one non-metallic rear roller rotatable on the body and having a rolling periphery configured to lie in rolling contact with the wafer holder when the latch body is connected thereto by the mounting post;
• the non-metallic front roller being rotatable on the body about a transverse axis perpendicular to and intersecting the mounting axis;
• and
• the at least one non-metallic rear roller being rotatable on the body about the transverse axis and is located opposite the mounting axis from the front roller, the rolling peripheries of the front and rear rollers being equidistant from the mounting axis and the gripping periphery being at a greater distance from the mounting axis than are the rolling peripheries.

A wafer mounting ring assembly comprising:

• a wafer mounting ring having a back side, having an inner edge, and a front side and an annular wafer engaging surface on the inner edge of its back side;
• a plurality of at least three latch assemblies each pivotally mounted to the back side of the mounting ring around the axis, each latch assembly having:
• a mounting post fixed and perpendicular to the back side of the mounting ring,
• a non-metallic latch body pivotally and resiliently mounted to the mounting ring at the mounting post so as to be biased toward the mounting ring and rotatable through approximately 90.degree. between a latched position and an unlatched position;
• a non-metallic front roller rotatable on the body about an axis perpendicular to and intersecting the mounting post, the front roller having a gripping periphery which lies adjacent the wafer engaging surface of the mounting ring when the latch assembly is rotated to its latched position and a rolling periphery which lies on a circle around the mounting post on the back side of the wafer mounting ring, and
• at least one non-metallic rear roller rotatable on the body about an axis perpendicular to and intersecting the mounting post, the rear roller having a rolling periphery lying on the circle;
• and
• a plurality of detents in the back side of the wafer mounting ring lying on said circle to receive the rolling peripheries of the front and rear rollers when the latch assemblies are in their unlatched positions or the latched positions.