WO2011016471A1 - 薄膜積層体の製造装置 - Google Patents
薄膜積層体の製造装置 Download PDFInfo
- Publication number
- WO2011016471A1 WO2011016471A1 PCT/JP2010/063151 JP2010063151W WO2011016471A1 WO 2011016471 A1 WO2011016471 A1 WO 2011016471A1 JP 2010063151 W JP2010063151 W JP 2010063151W WO 2011016471 A1 WO2011016471 A1 WO 2011016471A1
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- WO
- WIPO (PCT)
- Prior art keywords
- thin film
- roll
- flexible substrate
- winding
- strip
- Prior art date
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/56—Apparatus specially adapted for continuous coating; Arrangements for maintaining the vacuum, e.g. vacuum locks
- C23C14/562—Apparatus specially adapted for continuous coating; Arrangements for maintaining the vacuum, e.g. vacuum locks for coating elongated substrates
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H23/00—Registering, tensioning, smoothing or guiding webs
- B65H23/02—Registering, tensioning, smoothing or guiding webs transversely
- B65H23/032—Controlling transverse register of web
- B65H23/0324—Controlling transverse register of web by acting on lateral regions of the web
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H23/00—Registering, tensioning, smoothing or guiding webs
- B65H23/02—Registering, tensioning, smoothing or guiding webs transversely
- B65H23/032—Controlling transverse register of web
- B65H23/038—Controlling transverse register of web by rollers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H23/00—Registering, tensioning, smoothing or guiding webs
- B65H23/04—Registering, tensioning, smoothing or guiding webs longitudinally
- B65H23/18—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web
- B65H23/195—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web in winding mechanisms or in connection with winding operations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H23/00—Registering, tensioning, smoothing or guiding webs
- B65H23/04—Registering, tensioning, smoothing or guiding webs longitudinally
- B65H23/26—Registering, tensioning, smoothing or guiding webs longitudinally by transverse stationary or adjustable bars or rollers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2301/00—Handling processes for sheets or webs
- B65H2301/30—Orientation, displacement, position of the handled material
- B65H2301/32—Orientation of handled material
- B65H2301/323—Hanging
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2301/00—Handling processes for sheets or webs
- B65H2301/50—Auxiliary process performed during handling process
- B65H2301/51—Modifying a characteristic of handled material
- B65H2301/511—Processing surface of handled material upon transport or guiding thereof, e.g. cleaning
- B65H2301/5114—Processing surface of handled material upon transport or guiding thereof, e.g. cleaning coating
- B65H2301/51145—Processing surface of handled material upon transport or guiding thereof, e.g. cleaning coating by vapour deposition
Definitions
- a substrate for a thin film laminate such as a semiconductor thin film As a substrate for a thin film laminate such as a semiconductor thin film, a highly rigid substrate is usually used. However, a flexible substrate such as a resin is used as a substrate of a photoelectric conversion element used for, for example, a solar cell for convenience such as light weight and easy handling and cost reduction due to mass production. .
- the width direction of the strip-shaped flexible substrate is held in the horizontal direction, the flexible substrate is transported in the horizontal direction, and film formation is performed, and the width direction of the strip-shaped flexible substrate
- film formation is performed by holding the substrate in the vertical direction and transporting the flexible substrate in the horizontal direction.
- the latter type has the advantage that the surface of the flexible substrate is less likely to be contaminated than the former type.
- the flexibility is increased due to gravity and the extension of the flexible substrate due to its own weight.
- wrinkles occur on the surface of the conductive substrate, the flexible substrate meanders in the width direction, or hangs downward.
- an intermediate chamber is disposed between two film forming chambers located at the center of the plurality of film forming chambers arranged here, and the entire width of the flexible substrate is here.
- EPC edge position control
- JP 2009-46285 A Patent Document 1
- the flexible substrate is rapidly cooled and wrinkles are generated.
- the EPC roll since the balance of the tension acting on the flexible substrate is lost, creases tend to occur. In general, the EPC roll is more expensive than the transport roll.
- the winding roll when winding the strip-shaped flexible substrate on which the thin film has been formed, that is, the thin film laminate, by the winding roll, the winding roll has a very large binding force.
- the winding roll In order to control the height of the flexible substrate, it is necessary to take a distance between the winding roll and the grip roller. However, if the distance is taken, the belt-like flexible substrate, that is, the thin film laminate, becomes loose. . Further, if the position of the thin film laminate is lowered, a deviation occurs when the thin film laminate is wound on the take-up roll, and the film cannot be wound uniformly.
- An object of this invention is to provide the manufacturing apparatus of the thin film laminated body which can prevent the slack at the time of conveyance of a strip
- the present invention conveys the band-shaped flexible substrate in the horizontal direction so that the width direction of the band-shaped flexible substrate wound in a roll shape is in a vertical posture, and the band-shaped flexible substrate
- a film forming chamber is provided in the transport direction of the conductive substrate, the belt-shaped flexible substrate is transported to the film forming chamber, and a thin film is formed on the belt-shaped flexible substrate by the film forming apparatus provided in the film forming chamber.
- a strip-shaped flexible film is formed between the grip roller and the windup device in the preceding stage of the winding device for winding the thin film laminate in a roll shape.
- a thin film laminate manufacturing apparatus that winds in a roll shape with the width direction of either a horizontal posture or a vertical posture, a grip roller and a winding device are provided in a stage preceding the winding device that winds the thin film laminate in a roll shape Arise between This adjustment roll is provided with an adjustment roll that can prevent slack of the flexible substrate and suppress the influence of the change in the holding angle caused by the increase in the diameter of the take-up roll during winding and the transport trajectory of the belt-like flexible substrate.
- a pair of grip rollers that sandwich and convey at least one end portion in the width direction of the thin film stack are disposed in the previous stage.
- the present invention is provided with a detection device that detects an approach angle of the thin film laminate with respect to the adjustment roll, and controls at least one of the inclination angle and the applied pressure of the grip roller based on the detection data of the detection device. It is in.
- the present invention lies in that an LPC roll capable of moving the position of the belt-like flexible substrate in the width direction is used as the winding roll.
- the LPC roll is used as the winding roll, it is possible to eliminate the slippage associated with the winding of the thin film stack.
- the adjustment roll is provided in the front stage of the winding device, it is possible to prevent the slack of the belt-like flexible substrate generated between the grip roller and the winding device, and at the time of winding. It is possible to suppress the change in the holding angle due to the increase in the winding roll diameter and the influence of the transport path of the belt-like flexible substrate.
- the grip roller and the adjustment roll an alternative structure of the EPC roll can be obtained. Moreover, since it becomes a cheap structure compared with an EPC roll, it is economical.
- the approach angle of the thin film stack can be reduced to keep the thin film stack at the reference position.
- the LPC roll is used as the winding roll, it is possible to eliminate the slippage associated with the winding of the thin film stack.
- FIG. 1A and 1B show a thin film laminate manufacturing apparatus according to an embodiment of the present invention, in which FIG. 1A is a front view and FIG. 1B is a cross-sectional view taken along line BB in FIG. (A) is the elements on larger scale of Drawing 1 (a), and (b) is a top view of Drawing 2 (a).
- the other embodiment of this invention is shown, (a) is a front view, (b) is a front view of Fig.3 (a).
- 4 shows a thin film laminate manufacturing apparatus according to another embodiment of the present invention for conveying a thin film laminate in the vertical direction, where (a) is a front view and (b) is a CC line in FIG. 4 (a). It is sectional drawing.
- (A) is the elements on larger scale of FIG. 4 (a),
- (b) is a right view of FIG. 5 (a).
- FIG. 1A shows an unwinding roll 2 in which a belt-like flexible substrate 1 is wound in a roll shape, a film-forming chamber 3 for forming a film on the belt-like flexible substrate 1, and film-forming in the film-forming chamber 3.
- the applied thin film laminated body 1A is conveyed and the winding roll 4 which winds this thin film laminated body 1A with a fixed height is shown.
- the gas atmosphere is applied to the strip-shaped flexible substrate 1 that is conveyed in the horizontal direction from the unwinding roll 2 in which the strip-shaped flexible substrate 1 is wound in a roll shape.
- the thin film stack 1 ⁇ / b> A formed by plasma discharge in the film forming chamber 3 is sequentially wound by a winding roll 4 that is a winding device.
- a high-frequency electrode 5 and a ground electrode 6 with a built-in heater are opposed to each other, and the inside of the film forming chamber 3 is evacuated to generate plasma discharge in a gas atmosphere.
- a film is formed on the flexible substrate 1 disposed between the electrodes 5 and 6.
- the winding roll 4 is rotationally driven by a vertical axis, and the roll diameter gradually increases as the thin film stack 1A is wound.
- a pair of upper and lower grip rollers 7, 8 are provided on the upstream side of the winding roll 4, and these grip rollers 7, 8 hold the thin film stack 1 ⁇ / b> A while sandwiching the upper and lower ends of the thin film stack 1 ⁇ / b> A.
- the upper grip 7 may be used to sandwich only the upper end portion of the thin film laminate 1A. good.
- the adjusting roll 9 to be applied is provided, and this adjusting roll 9 sends the thin film laminated body 1A to the winding roll 4 with a constant trajectory while applying tension to the thin film laminated body 1A.
- the thin film laminate 1 ⁇ / b> A contacts the adjustment roll 9 with a winding angle (holding angle) so that the direction of conveyance to the winding roll 4 is changed, and the winding is performed. Tension is generated at the roll 4.
- the grip rollers 7, 8 are a pair of upper side grip rollers 7 that guide the upper side of the thin film laminate 1 ⁇ / b> A, that is, one side of the thin film laminate 1 ⁇ / b> A that is transported with the width direction oriented in the vertical direction. It comprises a pair of lower side grip rollers 8 that sandwich and guide the lower side of the body 1, that is, both sides of the other side.
- the pair of upper side grip rollers 7 are rotationally driven in opposite directions by vertical axes, respectively, and convey both sides of the upper side of the thin film stack 1 with a constant pressure.
- the pair of lower-side grip rollers 8 are also driven to rotate in the opposite directions by the vertical axes, similarly to the upper-side grip roller 7, and the other surfaces on the lower side of the thin film laminate 1A are fixed. It is sandwiched and transported at a pressure of.
- Sensors 10 and 11 for detecting positions are respectively provided at the front and rear stages of the adjustment roll 9.
- optical sensors or the like are used as the sensors 10 and 11.
- the sensor 10 detects the angle of entry of the thin film laminate 1 ⁇ / b> A into the adjustment roll 9, and the sensor 11 detects the angle of entry into the take-up roll 4. Based on the detection result of the approach angle, the applied pressure of the grip rollers 7 and 8 is adjusted.
- the sensors 10 and 11 can detect the position with respect to each thin film laminated body 1A, for example, and can detect the approach angle with respect to the thin film laminated body 1A from the difference of the position.
- the pressurizing force of the grip rollers 7 and 8 is controlled by the control device 12, and the control device 12 calculates the necessary pressurizing force based on the detection results from the sensors 10 and 11.
- the belt-like flexible substrate 1 that has been transported with the width direction oriented in the vertical direction is subjected to film formation by plasma discharge in the film formation chamber 3, and the grip roller 7 is formed as a thin film laminate 1A. , 8 are sent while being sandwiched. And this thin film laminated body 1A is wound around the winding roll 4 via the adjustment roll 9.
- the approach angle entering the adjustment roll 9 is detected by the sensors 10 and 11, the detection result is sent to the control device 12, and the applied pressure of the grip rollers 7 and 8 provided in the previous stage of the adjustment roll 9 is adjusted.
- the thin film laminate 1A is prevented from slackening or drooping, and the thin film laminate 1A is wound around the take-up roll 4 at a constant height.
- the winding roll 13 can be moved up and down to change the position of the winding roll 13 as shown in FIG.
- the height of the take-up roll 13 can be adjusted according to the height that has been conveyed to prevent the winding deviation of the thin film laminate 1 ⁇ / b> A from the take-up roll 13. Further, the height of the thin film laminate 1 ⁇ / b> A can be controlled by the grip rollers 7, 8 to control the occurrence of the entrance angle of the thin film laminate 1 ⁇ / b> A to the adjustment roll 9.
- the winding roll 13 can change the position of the winding roll 13 itself corresponding to the height position of the thin film laminate 1 ⁇ / b> A by the sensor 11 installed between the adjustment roll 9 and the winding roll 13.
- the height change of the thin film laminate 1A due to the approach angle of the thin film laminate 1A to the adjustment roll 9 that could not be suppressed by the grip rollers 7 and 8 is measured by the sensor 10, and the height of the winding roll 13 is adjusted.
- the winding accuracy of the winding roll 13 is further improved. be able to.
- Adopting an LPC roll as the winding roll 13 increases the cost, but is less expensive than the EPC roll.
- FIGS. 1 (a) and 1 (b) show another embodiment of a manufacturing apparatus for a thin film laminate that conveys the thin film laminate in the vertical direction, and the same parts as in FIGS. 1 (a) and 1 (b) have the same reference numerals. Will be described. 5 (a) and 5 (b) are enlarged views of the winding device portion of FIG. 4 (a).
- FIG. 4A shows an unwinding roll 22 in which the belt-like flexible substrate 21 is wound in a roll shape so as to convey the belt-like flexible substrate 21 in the vertical direction, and a film is formed on the belt-like flexible substrate 21.
- a substrate processing step 23 which is a processing chamber for patterning the film forming chamber or the strip-shaped flexible substrate 21, and a thin film stack 21 A formed in the substrate processing step 23 are transported, and this thin film stacking is performed.
- the winding roll 24 which winds up the body 21A is shown.
- the unwinding roll 22 in which the strip-shaped flexible substrate 21 is wound in a roll shape is configured so that the strip-shaped flexible substrate 21 is moved up and down and from the ceiling to the floor in at least a part of the transport process. It is arranged to convey from the floor to the ceiling.
- a substrate processing step unit 23 is disposed in the middle of the strip-shaped flexible substrate 21 conveyed from the ceiling to the floor, and the strip-shaped flexible substrate 21 is formed by plasma discharge in a deposition chamber in a gas atmosphere.
- a patterning process is performed on the belt-like flexible substrate 21 by a laser patterning apparatus.
- the thin film laminate 21A that has been subjected to film formation by plasma discharge or that has been subjected to laser patterning is sequentially wound by a winding roll 24 that is a winding device disposed on the floor side.
- the film forming chamber is a flexible structure disposed between the electrodes 25 and 26 by evacuating the film forming chamber 23 and generating plasma discharge in a gas atmosphere.
- the film is formed on the conductive substrate 21.
- the winding roll 24 is rotationally driven by an axis in the width direction of the thin film laminate 21A, and the roll diameter gradually increases as the thin film laminate 21A is wound.
- a pair of grip rollers 27 and 28 are provided on the upstream side of the take-up roll 24 in the width direction, and the grip rollers 27 and 28 sandwich the thin film stack 21A while sandwiching the upper end and the lower end of the thin film stack 21A.
- the body 21A is conveyed.
- the thin film laminate 21A is sent to the take-up roll 24 with a constant trajectory while applying tension to the laminate 21A.
- the unwinding roll 22 and the winding roll 24 are arranged so that the width direction of the strip-shaped flexible substrate 21 and the thin film laminate 21A is in the horizontal direction with respect to the floor.
- the width direction of the strip-like flexible substrate 21 and the thin film laminate 21A is in the vertical posture, and the substrate processing step unit 23 conveys it in the vertical direction. Form may be sufficient.
- the grip roller 27 may be arranged at least on the upper side, and when the conveying direction is up and down, the grip roller 27 and 28 need to sandwich both sides in the width direction of the belt-like flexible substrate 21 and the thin film laminate 21A.
- the pair of other-side grip rollers 28 are respectively driven to rotate in opposite directions by the axis in the width direction of the thin-film stack 21A.
- the both sides of the other side in the width direction are sandwiched and conveyed with a constant pressure.
- sensors 10 and 11 for detecting the position are respectively provided at the front and rear stages of the adjustment roll 29. These sensors 10 and 11 are, for example, optical sensors or the like.
- the approach angle of the thin film laminate 21A to the adjustment roll 29 is detected. Based on the detection result of the approach angle, the pressing force of the grip rollers 27 and 28 is adjusted.
- the sensors 10 and 11 can detect the position with respect to each thin film laminated body 21A, for example, and can detect the approach angle with respect to the thin film laminated body 21A from the difference of the position.
- the pressurizing force of the grip rollers 27 and 28 is controlled by the control device 12, and the control device 12 calculates the necessary pressurizing force based on the detection results from the sensors 10 and 11.
- belt-shaped flexible substrate 21 is conveyed in the up-down direction from the unwinding roll 22 which wound the strip
- the belt-like flexible substrate 21 transported from the ceiling to the floor is subjected to film formation by plasma discharge in the substrate processing step unit 23, and is sent while being sandwiched between grip rollers 27 and 28 as a thin film laminate 21A.
- the thin film laminate 21 ⁇ / b> A is wound around the winding roll 24 via the adjustment roll 29.
- the inclination angle of the grip roller 8 can be set so that the pair of grip rollers 8 on the lower side is kept horizontal.
- the grip rollers 7 and 8 can be used for both adjusting the pressure and adjusting the inclination angle.
- the approach angle was detected by the sensors 10 and 11, you may detect an approach angle by another method.
- the said embodiment demonstrated the conveyance to a single direction, it is applicable also when conveying in two directions. In this case, the same action can be obtained by providing the adjusting rolls 9 and 29 and the grip rollers 7, 8, 27 and 28 on the unwinding rolls 2 and 22.
- the sensors 10 and 11 can be appropriately changed and implemented within a range that does not change the gist of the present invention, such as being arranged with the adjustment rolls 9 and 29 interposed therebetween.
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Abstract
Description
しかしながら、通常、成膜は比較的に高い温度で行われることから、このようなステンレス製のEPCローラを成膜室の間に配置すると、可撓性基板が急冷され、皺が発生するなどの問題がある。
また、巻取りロールの巻きずれを防止するためには、EPCロールを採用することが望ましいが、EPCロールでは、可撓性基板に働く張力のバランスが崩れるため、折れ皺が発生し易い。また、通常、搬送ロールに比べEPCロールは高価である。
このように、複数の成膜室のそれぞれの間に、帯状可撓性基板の鉛直方向上側の端部を挟む少なくとも一対のグリップローラを配置し、これら複数対の鉛直方向上側端部のグリップローラを、各ローラの回転方向が、帯状可撓性基板の搬送方向に対して上方に傾くように設置することで、帯状可撓性基板が水平方向に搬送される際に、可撓性基板を上方に持ち上げる力が発生する。よって、帯状可撓性基板を複数の成膜室の間を長い距離にわたって搬送しても、可撓性基板に皺が発生したり、可撓性基板が幅方向に蛇行したり、可撓性基板が下方へ垂れ下がったりするのを防ぐことができ、帯状可撓性基板の鉛直方向における位置を精度高く維持することができる。
また、本発明は、前記調整ロールに対する薄膜積層体の進入角度を検出する検出装置を設け、該検出装置の検出データに基づいて前記グリップローラの傾斜角度あるいは加圧力の少なくともいずれかを制御したことにある。
さらに本発明は、前記巻取りロールに、帯状可撓性基板の幅方向に位置移動が可能なLPC(Line Position Control)ロールを用いたことにある。
またさらに、本発明は、ロール状に巻かれた帯状可撓性基板を上下方向に搬送し、該帯状可撓性基板の搬送方向に成膜室あるいは、帯状可撓性基板へのパターニング加工を行う加工処理室である基板処理工程部を設け、該基板処理工程部に、帯状可撓性基板を搬送して、前記基板処理工程部は、成膜室に設けられた成膜装置によって帯状可撓性基板に薄膜を成膜、あるいは加工処理室に設けられたパターニング装置によって帯状可撓性基板にパターニング加工する上下方向搬送系を少なくとも一部に有して薄膜積層体を帯状可撓性基板の幅方向が横姿勢あるいは縦姿勢のいずれかで、ロール状に巻き取る薄膜積層体の製造装置において、前記薄膜積層体をロール状に巻き取る巻取り装置の前段に、グリップローラと巻取り装置との間で生じる帯状可撓性基板の弛みを防止することができるとともに、巻取り時の巻取りロール径増加による抱き角変化と帯状可撓性基板の搬送軌道の影響を抑制する調整ロールを設け、この調整ロールの前段に、前記薄膜積層体の幅方向の少なくとも一端部を挟持して搬送する一対のグリップローラを配置したことにある。
また、本発明は、前記調整ロールに対する薄膜積層体の進入角度を検出する検出装置を設け、該検出装置の検出データに基づいて前記グリップローラの傾斜角度あるいは加圧力の少なくともいずれかを制御したことにある。
さらに、本発明は、前記巻取りロールに、帯状可撓性基板の幅方向の位置移動が可能なLPCロールを用いたことにある。
請求項2によれば、薄膜積層体の進入角度を小さくして薄膜積層体を基準位置に保つことができる。
請求項3によれば、巻取りロールに、LPCロールを用いたので、薄膜積層体の巻取りにともなうずれをなくすことができる。
請求項4によれば、巻取り装置の前段に調整ロールを設けたので、グリップローラと巻取り装置との間で生じる帯状可撓性基板の弛みを防止することができるとともに、巻取り時の巻取りロール径増加による抱き角変化と帯状可撓性基板の搬送軌道の影響を抑制することができる。グリップローラと、調整ロールを組み合わせることで、EPCロールの代替構造とすることができる。また、EPCロールに比べて安価な構造となるので、経済的である。
請求項5によれば、薄膜積層体の進入角度を小さくして薄膜積層体を基準位置に保つことができる。
請求項6によれば、巻取りロールに、LPCロールを用いたので、薄膜積層体の巻取りにともなうずれをなくすことができる。
図1(a)は、帯状可撓性基板1をロール状に巻いた巻出しロール2と、帯状可撓性基板1に成膜を施す成膜室3と、成膜室3において成膜を施された薄膜積層体1Aが搬送されて、この薄膜積層体1Aを一定の高さを保持して巻き取る巻取りロール4とを示したものである。
巻取りロール4は垂直軸によって回転駆動されるもので、薄膜積層体1Aの巻取りに従ってロール径が次第に増加するものである。この巻取りロール4の上流側には、上下一対のグリップローラ7,8が設けられ、これらグリップローラ7,8は、薄膜積層体1Aの上端部および下端部を挟持しながら薄膜積層体1Aを搬送するものであるが、本実施例のような可撓性基板幅方向を縦姿勢で搬送する場合には、上側のグリップ7で薄膜積層体1Aの上端部だけを挟持して搬送しても良い。
巻取りロール4の前段、すなわち、巻取りロール4とグリップローラ7,8との間には、一定の径を有し、薄膜積層体1Aが巻き付け角(抱角)を持って接して張力を付与する調整ロール9が設けられており、この調整ロール9は、薄膜積層体1Aに張力を付与しながら一定の軌跡で巻取りロール4に薄膜積層体1Aを送るものであり、具体的には、図2(b)に示すように、調整ロール9で薄膜積層体1Aが巻き付け角(抱角)を有して接することで、巻取りロール4に搬送する方向を変えるようして、巻取りロール4で張力が発生するようにする。
前記グリップローラ7,8の加圧力は、制御装置12によってそれぞれ制御されており、制御装置12は、センサ10,11からの検出結果により必要な加圧力を算定するものである。
図4(a)は、帯状可撓性基板21を上下方向に搬送するように帯状可撓性基板21をロール状に巻いた巻出しロール22と、帯状可撓性基板21に成膜を施す成膜室もしくは帯状可撓性基板21にパターニングを行う加工処理室である基板処理工程部23と、基板処理工程部23において成膜を施された薄膜積層体21Aが搬送されて、この薄膜積層体21Aを巻き取る巻取りロール24とを示したものである。
例えば、天井から床方向に搬送されてくる帯状可撓性基板21の途中に基板処理工程部23が配置され、帯状可撓性基板21をガス雰囲気中の成膜室で、プラズマ放電によって成膜を施すか、レーザパターニング装置によって、帯状可撓性基板21にパターニング処理を施すものである。プラズマ放電によって成膜を施こされたか、レーザパターニング処理された薄膜積層体21Aは、床側に配置された巻取り装置である巻取りロール24によって順次巻き取られていくものである。成膜室は、前記実施の形態と同様に、この成膜室23内を真空引き状態にして、ガス雰囲気中でプラズマ放電を発生させて、これら両電極25,26間に配置された可撓性基板21に成膜を施すものである。
巻取りロール24は薄膜積層体21Aの幅方向の軸によって回転駆動されるもので、薄膜積層体21Aの巻取りに従ってロール径が次第に増加するものである。この巻取りロール24の上流側には、幅方向で各一対のグリップローラ27,28が設けられ、これらグリップローラ27,28は、薄膜積層体21Aの上端部および下端部を挟持しながら薄膜積層体21Aを搬送するものである。巻取りロール24の前段、すなわち、巻取りロール24とグリップローラ27,28との間には、一定の径を有し、グリップローラと巻取り装置との間で生じる帯状可撓性基板の弛みを防止することができるとともに、巻取り時の巻取りロール径増加による抱き角変化と帯状可撓性基板の搬送軌道の影響を抑制する調整ロール29が設けられており、この調整ロール29は薄膜積層体21Aに張力を付与しながら一定の軌跡で巻取りロール24に薄膜積層体21Aを送るものである。
本実施形態においては、巻出しロール22と巻取りロール24を、帯状可撓性基板21、薄膜積層体21Aの幅方向が床と水平方向になるように配置する構成としているが、これに限定されるものではなく、巻出しロール22と巻取りロール24は、帯状可撓性基板21、薄膜積層体21Aの幅方向が縦姿勢となっていて、基板処理工程部23が上下方向に搬送する形態でも良い。
また、帯状可撓性基板21、薄膜積層体21Aの搬送姿勢が、縦姿勢の場合は、グリップローラ27は、少なくとも上側が配置されていれば良く、搬送方向が上下の場合には、グリップローラ27,28によって、帯状可撓性基板21、薄膜積層体21Aの幅方向の両側を挟持する必要がある。
前記グリップローラ27,28の加圧力は、制御装置12によってそれぞれ制御されており、制御装置12は、センサ10,11からの検出結果により必要な加圧力を算定するものである。
なお、上記実施の形態では、巻取りロール24に、図3の実施の形態で説明した、LPCロールを採用することもできる。
この場合、巻取りロール24にLPCロールを採用することで、巻取りに際して、図示二点鎖線のように昇降して位置を変えることができるので、薄膜積層体21Aの幅方向の位置を調整して薄膜積層体21Aの巻きずれを防止することができる。
また、上記実施の形態では、センサ10,11によって進入角を検出しているが、他の方法によって進入角を検出しても良い。また、上記実施の形態では、単方向への搬送について説明したが双方向に搬送する場合にも適用することができる。この場合、巻き出しロール2,22にも調整ロール9,29およびグリップローラ7,8,27,28を設けることで同様の作用を得ることができる。また、センサ10,11についても調整ロール9,29を挟んで配設することができるなど、その他、本発明の要旨を変更しない範囲内で、適宜、変更して実施し得ることは言うまでもない。
Claims (6)
- ロール状に巻かれた帯状可撓性基板の幅方向が縦姿勢になるようにして、帯状可撓性基板を横方向に搬送し、該帯状可撓性基板の搬送方向に成膜室を設け、該成膜室に、帯状可撓性基板を搬送して、成膜室に設けられた成膜装置によって帯状可撓性基板に薄膜を成膜して薄膜積層体をロール状に巻き取る薄膜積層体の製造装置において、前記薄膜積層体をロール状に巻き取る巻取り装置の前段にグリップローラと巻取り装置との間で生じる帯状可撓性基板の弛みを防止することができるとともに、巻取り時の巻取りロール径増加による抱き角変化と帯状可撓性基板の搬送軌道の影響を抑制する調整ロールを設け、この調整ロールの前段に、前記薄膜積層体の少なくとも上端部を挟持して一定の高さを保持して搬送する一対のグリップローラを配置したことを特徴とする薄膜積層体の製造装置。
- 前記調整ロールに対する薄膜積層体の進入角度を検出する検出装置を設け、該検出装置の検出データに基づいて前記グリップローラの傾斜角度あるいは加圧力の少なくともいずれかを制御したことを特徴とする請求項1に記載の薄膜積層体の製造装置。
- 前記巻取りロールに、帯状可撓性基板の幅方向に位置移動が可能なLPCロールを用いたことを特徴とする請求項2に記載の薄膜積層体の製造装置。
- ロール状に巻かれた帯状可撓性基板を上下方向に搬送し、該帯状可撓性基板の搬送方向に成膜室あるいは、帯状可撓性基板へのパターニング加工を行う加工処理室である基板処理工程部を設け、該基板処理工程部に、帯状可撓性基板を搬送して、前記基板処理工程部は、成膜室に設けられた成膜装置によって帯状可撓性基板に薄膜を成膜、あるいは加工処理室に設けられたパターニング装置によって帯状可撓性基板にパターニング加工する上下方向搬送系を少なくとも一部に有して薄膜積層体を帯状可撓性基板の幅方向が横姿勢あるいは縦姿勢のいずれかでロール状に巻き取る薄膜積層体の製造装置において、前記薄膜積層体をロール状に巻き取る巻取り装置の前段にグリップローラと巻取り装置との間で生じる帯状可撓性基板の弛みを防止することができるとともに、巻取り時の巻取りロール径増加による抱き角変化と帯状可撓性基板の搬送軌道の影響を抑制する調整ロールを設け、この調整ロールの前段に、前記薄膜積層体の幅方向の少なくとも一端部を挟持して搬送する一対のグリップローラを配置したことを特徴とする薄膜積層体の製造装置。
- 前記調整ロールに対する薄膜積層体の進入角度を検出する検出装置を設け、該検出装置の検出データに基づいて前記グリップローラの傾斜角度あるいは加圧力の少なくともいずれかを制御したことを特徴とする請求項4に記載の薄膜積層体の製造装置。
- 前記巻取りロールに、帯状可撓性基板の幅方向の位置移動が可能なLPCロールを用いたことを特徴とする請求項5に記載の薄膜積層体の製造装置。
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EP10806470.0A EP2463402A4 (en) | 2009-08-06 | 2010-08-04 | DEVICE FOR PRODUCING A THIN FILM COATING |
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US20150344347A1 (en) * | 2014-05-29 | 2015-12-03 | Corning Incorporated | Apparatuses for steering flexible glass webs and methods for using the same |
DE102018215100A1 (de) | 2018-05-28 | 2019-11-28 | Sms Group Gmbh | Vakuumbeschichtungsanlage, und Verfahren zum Beschichten eines bandförmigen Materials |
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JPWO2011016471A1 (ja) | 2013-01-10 |
EP2463402A4 (en) | 2014-01-15 |
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