What is claimed is:
1. A plasma processing apparatus comprising:
a vacuum chamber accommodating therein a substrate to be processed, allowing an inner space of the vacuum chamber to be maintained at a vacuum level;
a first electrode fixedly disposed at a location in the vacuum chamber;
a second electrode installed in the vacuum chamber and facing the first electrode, the second electrode being vertically movable so as to vary a distance between the first electrode and the second electrode;
a driving mechanism for vertically moving the second electrode, the driving mechanism being installed outside the vacuum chamber;
a bellows unit for air-tightly sealing an opening, the bellows unit having a frame-shaped member connected to the driving mechanism, wherein the opening, through which the second electrode is driven by the driving mechanism from the outside of the vacuum chamber, is provided at the vacuum chamber;
an electrode supporting member for connecting the frame-shaped member to the second electrode, the electrode supporting member being installed in the vacuum chamber; and
a high frequency power source generating plasma by supplying a high frequency power between the first electrode and the second electrode.
2. The plasma processing apparatus of claim 1, wherein the first electrode and the second electrode are a lower electrode and an upper electrode, respectively.
3. The plasma processing apparatus of claim 2, wherein the upper electrode is supported from underneath the lower electrode.
4. The plasma processing apparatus of claim 3, wherein the electrode supporting member includes an exhaust ring for uniformly exhausting the vacuum chamber.
5. The plasma processing apparatus of claim 3, wherein the electrode supporting member includes a cylindrical member for protecting an inner wall of the vacuum chamber.
6. The plasma processing apparatus of claim 3, further comprising a substrate supporting member for supporting the substrate to be processed above the lower electrode, the substrate supporting member being vertically movable by the driving mechanism to pass through the lower electrode.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A method of manipulating a substrate, the method comprising:
gripping a lower surface of the substrate with a master vacuum gripper mounted on a first motorized stage, wherein the master vacuum gripper is adapted to rotate about a Z-axis;
gripping the lower surface of the substrate with a slave vacuum gripper mounted on a second motorized stage, wherein the slave vacuum gripper is adapted to rotate about the Z-axis; and
actuating the second motorized stage in a first direction, thereby causing the slave vacuum gripper to move laterally in both the first direction and a second direction and the master vacuum gripper to rotate about the Z-axis.
2. The method of claim 1 wherein the master vacuum gripper and the slave vacuum gripper are adapted to move vertically along the Z-axis during actuation of the second motorized stage.
3. The method of claim 1 further comprising:
actuating the second motorized stage in the first direction; and
actuating the first motorized stage in the first direction, thereby indexing the substrate in the first direction.
4. The method of claim 3 wherein squaring and indexing operations are performed without releasing and re-gripping of the substrate.
5. The method of claim 1 wherein:
the first motorized stage comprises a plurality of motor controlled actuators in the first and second directions; and
the second stage motorized stage comprises a motor controlled actuator in the first direction.
6. The method of claim 5 wherein the second motorized stage comprises a flexible coupler compressible and extendable in the second direction.
7. The method of claim 6 wherein the first direction is a Y-direction and the second direction is an X-direction.
8. The method of claim 6 wherein the flexible coupler comprises a spring.
9. The method of claim 1 wherein the substrate comprises a glass panel suitable for flat panel displays.
10. An apparatus for manipulating a position of a substrate, the apparatus comprising:
a support member;
a plurality of support bars coupled to the support member and arrayed to form a parallel rank of support bars;
a first X-Y table coupled to the support member and adapted to translate under motor control in a Y-direction of an X-Y plane;
a second X-Y table coupled to the support member and adapted to translate under motor control in both the Y-direction and an X-direction of the X-Y plane;
a first vacuum gripper coupled to the first X-Y table and controllable in a Z-direction, wherein the first vacuum gripper is adapted to rotate about a Z-axis; and
a second vacuum gripper coupled to the second X-Y table and controllable in the z-direction, wherein the second vacuum gripper is adapted to rotate about the Z-axis.
11. The apparatus of claim 10 wherein an upper surface of the plurality of support bars defines a plane aligned with a lower portion of the substrate.
12. The apparatus of claim 10 wherein the first X-Y table comprises a spring constraining translation of the first X-Y table in the X-direction.
13. The apparatus of claim 10 wherein the first X-Y table and the second X-Y table are adapted to translate a distance greater than 2 meters in the Y-direction.
14. The apparatus of claim 10 wherein at least one of the first vacuum gripper or the second vacuum gripper comprises a gripping surface coupled to a gripper shaft extending into a tandem bearing, wherein the tandem bearing comprises:
a first air bearing characterized by a first diameter;
a second air bearing characterized by a second diameter less than the first diameter.
15. The apparatus of claim 14 wherein the first air bearing and the second air bearing are aligned concentric with a central axis of the tandem bearing.
16. The apparatus of claim 15 wherein the first air bearing is an upper bearing forming a portion of the tandem bearing proximate to the substrate and the second air bearing is a lower bearing forming an opposing portion of the tandem bearing.
17. A vacuum gripper for use in substrate positioning operations, the vacuum gripper comprising:
a vacuum pad adapted to make contact with the substrate;
a shaft connected to the vacuum pad, wherein the shaft is characterized by a first diameter at a portion of the shaft proximal to the vacuum pad and a second diameter at a portion of the shaft distal to the vacuum pad;
a first air bearing surrounding the portion of the shaft proximal to the vacuum pad;
a second air bearing surrounding the portion of the shaft distal to the vacuum pad;
an air source in fluid communication with the first air bearing and the second air bearing;
an exhaust port in fluid communication with the first air bearing and the second air bearing;
a valve in fluid communication with the exhaust port; and
a first flow restrictor in fluid communication with the valve.
18. The vacuum gripper of claim 17 further comprising a second flow restrictor in fluid communication with the valve, wherein the valve is adapted to place either the first flow restrictor or the second flow restrictor in fluid communication with the exhaust port.
19. The vacuum gripper of claim 18 wherein an orifice of the first flow restrictor is characterized by a diameter of different size than an orifice of the second flow restrictor.
20. The vacuum gripper of claim 17 wherein the valve is a solenoid valve.
21. The vacuum gripper of claim 17 wherein the first air bearing is a cylindrical bearing.
22. The vacuum gripper of claim 17 wherein the second air bearing is a cylindrical bearing.
23. The vacuum gripper of claim 17 wherein the first air bearing and the second air bearing comprise a porous material.
24. A method of translating a vacuum gripper adapted for use in substrate positioning operations, the vacuum gripper comprising a vacuum pad adapted to make contact with a substrate and a shaft connected to the vacuum pad, the method comprising:
receiving a gas at a first input port in fluid communication with a first air bearing surrounding a portion of the shaft proximal to the vacuum pad;
receiving the gas at a second input port in fluid communication with a second air bearing surrounding a portion of the shaft distal to the vacuum pad;
internally exhausting the gas through the first air bearing and the second air bearing into a plenum formed between the first air bearing and the second air bearing;
externally exhausting the gas through an outlet port in fluid communication with the plenum; and
actuating a valve to establish a differential pressure in the plenum and thereby translate the vacuum gripper.
25. The method of claim 24 wherein actuating the valve comprises externally exhausting the gas via either a first flow restrictor or a second flow restrictor, the first flow restrictor and the second flow restrictor being in fluid communication with the valve.
26. The method of claim 24 wherein the shaft is characterized by a first diameter at a portion of the shaft proximal to the vacuum pad and a second diameter at a portion of the shaft distal to the vacuum pad.
27. The method of claim 24 wherein the gas is pressurized air.
28. The method of claim 24 wherein the plenum comprises an annular region centered on a center line of the shaft and aligned with the outlet port.
29. The method of claim 24 wherein the vacuum gripper is translated along a direction parallel to a longitudinal axis of the shaft.
30. The method of claim 24 wherein the first air bearing and the second air bearing comprise a porous material.