WO2013076922A1 - 基板搬送ローラ、薄膜の製造装置及び薄膜の製造方法 - Google Patents
基板搬送ローラ、薄膜の製造装置及び薄膜の製造方法 Download PDFInfo
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- WO2013076922A1 WO2013076922A1 PCT/JP2012/006963 JP2012006963W WO2013076922A1 WO 2013076922 A1 WO2013076922 A1 WO 2013076922A1 JP 2012006963 W JP2012006963 W JP 2012006963W WO 2013076922 A1 WO2013076922 A1 WO 2013076922A1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/67—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
- H01L21/677—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere for conveying, e.g. between different workstations
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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
- C23C14/50—Substrate holders
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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
- C23C14/54—Controlling or regulating the coating process
- C23C14/541—Heating or cooling of the substrates
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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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- 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
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
- C23C16/458—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for supporting substrates in the reaction chamber
- C23C16/4582—Rigid and flat substrates, e.g. plates or discs
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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
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
- C23C16/46—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for heating the substrate
- C23C16/463—Cooling of the substrate
- C23C16/466—Cooling of the substrate using thermal contact gas
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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
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
- C23C16/54—Apparatus specially adapted for continuous coating
- C23C16/545—Apparatus specially adapted for continuous coating for coating elongated substrates
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/02104—Forming layers
- H01L21/02365—Forming inorganic semiconducting materials on a substrate
- H01L21/02518—Deposited layers
- H01L21/02521—Materials
- H01L21/02524—Group 14 semiconducting materials
- H01L21/02532—Silicon, silicon germanium, germanium
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/67—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
- H01L21/67005—Apparatus not specifically provided for elsewhere
- H01L21/67011—Apparatus for manufacture or treatment
- H01L21/67017—Apparatus for fluid treatment
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/04—Processes of manufacture in general
- H01M4/0402—Methods of deposition of the material
- H01M4/0421—Methods of deposition of the material involving vapour deposition
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
Definitions
- the present invention relates to a substrate transport roller, a thin film manufacturing apparatus, and a thin film manufacturing method.
- Thin film technology is widely deployed to improve the performance and miniaturization of devices.
- the thinning of devices is not only a direct merit for users, but also plays an important role in environmental aspects such as protecting earth resources and reducing power consumption.
- a winding-type thin film manufacturing method is a method in which a long substrate is unwound from an unwinding roll, a thin film is formed on the substrate while being transported along the transport system, and then the substrate is wound on the winding roll.
- a thin film can be formed with high productivity by combining a film formation source having a high deposition rate such as a vacuum evaporation source using an electron beam with a winding thin film manufacturing method.
- the factors that determine success or failure in the production of such a continuous winding type thin film include the problem of heat load during film formation and substrate cooling.
- thermal radiation from the evaporation source and thermal energy possessed by the evaporated atoms are applied to the substrate, and the temperature of the substrate rises.
- heat sources are different in other film formation methods, a thermal load is applied to the substrate during film formation.
- the substrate is cooled.
- the cooling is not necessarily performed during film formation, and may be performed in a substrate transport path other than the film formation region.
- Patent Document 1 provides a plurality of slits or holes in the cylindrical wall of the cylindrical body, a partition plate in the cylindrical body, and the cylinder with respect to the partition plate.
- a cooling roller is disclosed in which a body is slidably rotatable and a cooling gas jet pipe is provided in a chamber partitioned by the partition plate. According to this, by blowing a large amount of cooling gas to the slurry, it is possible to cool it by taking heat directly from the slurry.
- Patent Document 2 discloses that in an apparatus for forming a thin film on a web that is a substrate, a gas is introduced into a region between the web and a support means. According to this, since heat conduction between the web and the support means can be ensured, an increase in the temperature of the web can be suppressed.
- Patent Document 3 discloses a belt cooling method when a belt is used for transporting and cooling a substrate material. According to the method disclosed in Patent Document 3, when a cooling belt that improves thin film formation efficiency is used in a thin film forming apparatus that applies a thermal load, in order to further cool the cooling belt, a double or more inside is used. A cooling mechanism using a cooling belt or a liquid medium is provided. Thereby, since cooling efficiency can be improved, the characteristics of magnetic tape such as electromagnetic conversion characteristics can be improved, and at the same time, productivity can be remarkably improved.
- Patent Document 4 describes a substrate transport roller that is less susceptible to damage to a substrate and can suppress gas deterioration and gas cooling.
- the substrate transport roller (blow roller) described in FIG. 14 of Patent Document 4 includes an inner block, a first shell, and a second shell. Between the second shell and the inner block, a manifold into which a gas is introduced and a gap portion set other than the manifold are formed. Gas is supplied from the manifold to the back surface of the substrate through the plurality of first through holes formed in the first shell and the plurality of second through holes formed in the second shell. According to such a structure, the substrate can be cooled while suppressing the deterioration of the degree of vacuum. However, there is a possibility that foreign matters such as dust enter the through hole and the relative rotation between the inner block and the shell is hindered and the substrate may be damaged.
- An object of the present invention is to provide a technique for cooling a substrate in a vacuum while suppressing damage to the substrate.
- a substrate transport roller having a function of transporting a substrate in a vacuum and a function of supplying a gas for cooling the substrate toward the substrate in a vacuum;
- a cylindrical outer peripheral surface for supporting the substrate; and a plurality of first through holes provided along the circumferential direction of the outer peripheral surface as the gas supply path, and synchronized with the substrate.
- a first shell that can be rotated An inner block disposed inside the first shell and prohibited from rotating in synchronization with the substrate; A space defined by the inner block in the first shell so as to hold the gas introduced from the outside, and a plurality of spaces within a specific angle range around the rotation axis of the first shell.
- a manifold formed to guide the gas toward the first through hole and having a relatively wide dimension with respect to a radial direction of the first shell; A space formed inside the first shell, the gas being guided toward the plurality of first through holes outside the range of the specific angle, and relative to the radial direction; A gap having a narrow dimension, A second shell disposed between the first shell and the inner block and having a second through hole for guiding the gas from the manifold to the plurality of first through holes; With A substrate transport roller is provided in which a central axis of the first through hole is offset from a central axis of the second through hole.
- the rotation failure of the substrate transport roller can be prevented, and the substrate can be cooled in a vacuum while suppressing damage to the substrate.
- the first aspect of the present disclosure is: A substrate transport roller having a function of transporting a substrate in a vacuum and a function of supplying a gas for cooling the substrate toward the substrate in a vacuum; A cylindrical outer peripheral surface for supporting the substrate; and a plurality of first through holes provided along the circumferential direction of the outer peripheral surface as the gas supply path, and synchronized with the substrate.
- a first shell that can be rotated An inner block disposed inside the first shell and prohibited from rotating in synchronization with the substrate; A space defined by the inner block in the first shell so as to hold the gas introduced from the outside, and a plurality of spaces within a specific angle range around the rotation axis of the first shell.
- a manifold formed to guide the gas toward the first through hole and having a relatively wide dimension with respect to a radial direction of the first shell; A space formed inside the first shell, the gas being guided toward the plurality of first through holes outside the range of the specific angle, and relative to the radial direction; A gap having a narrow dimension, A second shell disposed between the first shell and the inner block and having a second through hole for guiding the gas from the manifold to the plurality of first through holes; With A substrate transport roller is provided in which a central axis of the first through hole is offset from a central axis of the second through hole.
- the central axis of the first through hole is offset from the central axis of the second through hole. Therefore, it is difficult for foreign matter to enter between the inner block and the second shell. Thereby, the rotation failure of the substrate transport roller is prevented, and it becomes possible to cool the substrate in a vacuum while suppressing damage to the substrate.
- the second aspect of the present disclosure provides, in addition to the first aspect, a substrate transport roller in which the first shell rotates in synchronization with the second shell.
- a substrate transport roller in which the first shell rotates in synchronization with the second shell.
- the second shell has an outer peripheral surface that is in close contact with the inner peripheral surface of the first shell, and the gap is formed between the second shell and the inner surface.
- a substrate transport roller formed between the blocks. According to such a configuration, foreign matter can be prevented from entering between the first shell and the second shell. In addition, since the heat transfer from the first shell to the second shell is good, the cooling efficiency of the substrate is increased.
- the first shell and the second shell are developed, and further, the first shell is arranged in a plane parallel to the surface of the first shell.
- a substrate transport roller is provided in which a contour of the first through hole is separated from a contour of the second through hole. According to such a structure, it can prevent more reliably that a foreign material penetrate
- the second shell further includes a concave portion formed at a position facing the first through hole, and the concave portion includes the concave portion.
- a substrate transport roller having a second through hole is provided. According to such a configuration, entry of foreign matter into the second through hole can be more effectively prevented.
- the sixth aspect of the present disclosure provides, in addition to the fifth aspect, a substrate transport roller in which a plurality of the first through holes face one concave portion. According to such a structure, it can avoid that the process for forming the recessed part of a 2nd shell by cutting becomes complicated.
- the second shell has a plurality of the second through holes, and the plurality of the second through holes have one recess.
- An open substrate transport roller is provided. According to such a structure, it can avoid that the process for forming the recessed part of a 2nd shell by cutting becomes complicated.
- the eighth aspect of the present disclosure in addition to any one of the first to seventh aspects, further includes a support body that supports the inner block, and the support body supplies the gas from the outside to the manifold.
- a substrate transport roller having a gas flow path for introduction is provided. According to such a configuration, a separate member for the gas flow path is not necessary.
- the first through hole has a diameter that decreases from the outer peripheral side of the first shell toward the center side.
- a substrate transport roller is provided.
- the second through hole has a diameter that decreases from an outer peripheral side to a center side of the second shell.
- a substrate transport roller is provided.
- the concave portion is located on an extension line of the central axis of the first through hole, and the second portion And a second portion having a through-hole, wherein a depth of the first portion is greater than a depth of the second portion. According to such a configuration, the foreign matter is easily captured by the first portion, and therefore the foreign matter is unlikely to reach the second through hole even if it can pass through the first through hole.
- the diameter of the second through hole on the outer peripheral side of the second shell is such that the first side on the center side of the first shell A substrate transport roller having a diameter smaller than that of the through hole is provided. According to such a relationship, it is possible to prevent foreign matters that are smaller than the diameter of the first through hole and larger than the diameter of the second through hole from entering the gap portion.
- the plurality of first through holes are (i) arranged in the circumferential direction at a predetermined position in a width direction parallel to the rotation axis. And (ii) a second group provided along the circumferential direction at a position adjacent to the predetermined position, and a plurality of the groups belonging to the first group A substrate transport roller is provided in which first through holes and a plurality of the first through holes belonging to the second group form an alternating arrangement. According to such an arrangement of the first through holes, more uniform cooling is possible.
- a fourteenth aspect of the present disclosure includes A vacuum chamber; A transport system having any one of the substrate transport rollers according to any one of the first to thirteenth aspects and disposed in the vacuum chamber so as to transport a long substrate from the unwinding position to the winding position; An opening provided in a transport path of the transport system; A deposition source for applying material to the substrate at the opening; An apparatus for manufacturing a thin film is provided.
- a fifteenth aspect of the present disclosure includes Using the substrate transport roller of any one of the first to thirteenth aspects to construct a long substrate transport system in the vacuum chamber; Transporting a long substrate from the unwinding position of the transport system to the winding position; Evaporating the material from the film forming source toward the opening provided in the transport path of the transport system so that the material is applied to the substrate; A method for producing a thin film is provided.
- the substrate can be cooled in vacuum while suppressing damage to the substrate, a high-quality thin film can be produced with high productivity.
- the thin film manufacturing apparatus 20 ⁇ / b> A includes a vacuum chamber 22, a transport system 36 ⁇ / b> A, a film forming source 19, a shielding plate 29, a source gas introduction pipe 30, and an exhaust pump 35.
- the conveyance system 36 ⁇ / b> A includes a winding core roller 23, a blow roller 6, a conveyance roller 24, a can 27, and a winding core roller 26.
- the blow roller 6 has a function of transporting the substrate 21 and a function of supplying a gas for cooling the substrate 21 toward the substrate 21.
- the blow roller 6 is also one of the transport rollers. Gas (cooling gas) is supplied from the outside of the vacuum chamber 22 to the blow roller 6 through the gas supply pipe 32.
- the type of gas to be introduced into the blow roller 6 is not particularly limited.
- oxygen gas, hydrogen gas, inert gas, etc. can be used.
- inert gas nitrogen gas, helium gas, neon gas, argon gas, xenon gas, krypton gas, or the like can be used.
- a plurality of types of gases may be mixed and used.
- the vacuum chamber 22 is a pressure-resistant container-like member having an internal space.
- a transfer system 36 ⁇ / b> A, a film forming source 19, and the like are arranged in the internal space of the vacuum chamber 22.
- the winding core roller 23 is a roller-like member provided so as to be rotatable around an axis.
- a belt-like long substrate 21 is wound on the surface of the winding core roller 23.
- the winding core roller 23 supplies the substrate 21 toward the transport roller (the blow roller 6 in FIG. 1) closest to the winding core roller 23.
- the exhaust pump 35 is provided outside the vacuum chamber 22 to bring the inside of the vacuum chamber 22 into a reduced pressure state suitable for forming a thin film.
- the exhaust pump 35 is configured by a vacuum exhaust system using, for example, an oil diffusion pump, a cryopump, a turbo molecular pump, or the like as a main pump.
- the substrate 21 can be a metal foil, a polymer film, a composite of a polymer film and a metal foil, or the like.
- the metal foil include aluminum foil, copper foil, nickel foil, titanium foil, and stainless steel foil.
- the polymer film include polyethylene terephthalate, polyethylene naphthalate, polyamide, and polyimide.
- the material of the substrate 21 is not particularly limited. As the substrate 21, a long substrate that is not limited to the above materials can be used.
- the width of the substrate 21 is, for example, 50 to 1000 mm.
- a desirable thickness of the substrate 21 is, for example, 3 to 150 ⁇ m. If the width of the substrate 21 is less than 50 mm, the gas loss in the width direction of the substrate 21 during gas cooling is large, but this does not mean that the present invention cannot be applied. If the thickness of the substrate 21 is less than 3 ⁇ m, the heat capacity of the substrate 21 is extremely small, and thermal deformation is likely to occur. However, none of them indicates that the present invention is not applicable.
- the conveyance speed of the substrate 21 varies depending on the type of thin film to be produced and the film formation conditions, but is, for example, 0.1 to 500 m / min.
- the tension applied to the substrate 21 being transferred is appropriately adjusted according to conditions such as the material of the substrate 21, the thickness of the substrate 21, and the film forming speed.
- the transport roller 24 is a roller-like member provided so as to be rotatable around an axis.
- the transport roller 24 guides the substrate 21 supplied from the winding core roller 23 to the film forming region and finally guides it to the winding core roller 26.
- the material particles flying from the film formation source 19 are introduced from the source gas introduction pipe 30 as necessary. And deposited on the substrate 21. Thereby, a thin film is formed on the surface of the substrate 21.
- the winding core roller 26 is a roller-like member that is rotatably provided by a driving means (for example, a motor) (not shown), and winds and stores the substrate 21 on which a thin film is formed.
- Various film forming sources can be used as the film forming source 19.
- an evaporation source, an ion plating source, a sputtering source, a CVD source, or the like by resistance heating, induction heating, electron beam heating, or the like can be used.
- an ion source or a plasma source in combination with the film forming source 19.
- the film forming source 19 is provided vertically below the opening 31.
- the film forming source 19 is a container-like member having an open top, and an evaporation crucible is a specific example. A material is placed inside the evaporation crucible.
- a heating means such as an electron gun is provided in the vicinity of the film forming source 19, and the material inside the evaporation crucible is heated and evaporated by the electron beam from the electron gun.
- the vapor of the material moves vertically upward and adheres to the surface of the substrate 21 through the opening 31. Thereby, a thin film is formed on the surface of the substrate 21.
- the shielding plate 29 restricts the region where the material particles flying from the film forming source 19 are in contact with the substrate 21 to the opening 31 only.
- the film forming apparatus 20 ⁇ / b> A may further include means for introducing a film forming gas for reaction film formation into the vacuum chamber 22.
- a means for introducing the film forming gas for example, the source gas introducing pipe 30 of FIG.
- the source gas introduction pipe 30 is, for example, a tubular member having one end disposed vertically above the film forming source 19 and the other end provided outside the vacuum chamber 22, and supplies oxygen, nitrogen, etc., to the material vapor, for example. To do.
- a thin film mainly composed of oxide, nitride or oxynitride of the material flying from the film forming source 19 is formed on the surface of the substrate 21.
- the source gas introduction pipe 30 is connected to a film forming reaction gas supply means (not shown). Examples of the film supply gas supply means include a gas cylinder and a gas generator.
- the substrate 21 on which the thin film is formed is wound around the winding core roller 26 via another conveying roller 24.
- the blow roller 6 is disposed in the middle of the substrate conveyance path from the winding core roller 23 to the winding core roller 26.
- the substrate 21 is cooled by the blow roller 6.
- Only one blow roller 6 may be provided in the transport system 36A, or a plurality of blow rollers 6 may be provided in the transport system 36A as in the present embodiment. Further, the blow roller 6 may be provided at a position where the substrate 21 before film formation can be cooled, or may be provided at a position where the substrate 21 after film formation can be cooled.
- a thin film manufacturing apparatus 20B includes a transport system 36B.
- a transport system 36B In the vacuum chamber 22, a plurality of film forming sources 19 and a plurality of openings 31 are provided.
- the transport system 36 ⁇ / b> B has a plurality of cans 27 and is configured to form thin films on both surfaces of the substrate 21.
- a plurality of blow rollers 6 are provided in the transport system 36B.
- the blow roller 6 includes a first shell 11, a second shell 13, an inner block 3, a key 5, a holding plate 51, a support body 10, and a bearing 18. Both the first shell 11 and the second shell 13 have a cylindrical shape.
- a second shell 13 is disposed inside the first shell 11.
- the inner block 3 is disposed inside the second shell 13.
- the first shell 11 and the second shell 13 are rotatably attached to the inner block 3 via a bearing 18.
- a manifold 4 and a gap 15 are formed inside the second shell 13, that is, inside the first shell 11.
- the first shell 11 has a cylindrical outer peripheral surface 11p for supporting the substrate 21, and a plurality of first through holes 12 provided along the circumferential direction LD of the outer peripheral surface 11p.
- the first through hole 12 serves as a gas supply path from the manifold 4 to the substrate 21.
- the first shell 11 is configured to be able to rotate in synchronization with the movement of the substrate 21.
- the second shell 13 is disposed between the first shell 11 and the inner block 3.
- the rotation axis of the second shell 13 coincides with the rotation axis O of the first shell 11.
- the second shell 13 has a plurality of second through holes 14 that guide gas from the manifold 4 to the plurality of first through holes 12 of the first shell 11.
- the number of second through holes 14 is not particularly limited.
- the rotational axes of the first shell 11 and the second shell 13 may or may not coincide with the center of the inner block 3.
- the space between the inner peripheral surface 13q of the second shell 13 and the outer peripheral surface 3p of the inner block 3 is relatively wide within the range of the holding angle, and the gap 15 is relatively outside the range of the holding angle.
- the positional relationship between the second shell 13 and the inner block 3 may be set so as to be narrowed.
- the central axis of the first through hole 12 is offset from the central axis of the second through hole 14. Therefore, it is difficult for foreign matter to enter between the inner block 3 and the second shell 13. Accordingly, the rotation failure of the blow roller 6 is prevented, and the substrate 21 can be cooled in a vacuum while suppressing damage to the substrate 21.
- the shape of the cross section of the first through hole 12 and the shape of the cross section of the second through hole 14 are not necessarily circular. That is, the shape of those cross sections may be polygonal or elliptical.
- “the central axis of the first through hole 12” and “the central axis of the second through hole 14” are determined by the following rule. First, the outer peripheral surface 11p of the first shell 11 is viewed in plan, and the opening of the first through hole 12 is observed. Next, the circle with the smallest diameter that can accommodate the observed opening is determined. An axis that passes through the center of the circle and is perpendicular to the rotation axis O can be regarded as a “center axis of the first through hole 12”. The central axis of the second through hole 14 can be determined by the same rule.
- the first shell 11 and the second shell 13 are developed, and the first shell 11 and the second shell 13 are projected (orthographically projected) on a plane parallel to the surface 11 p of the first shell 11. It corresponds to the projection figure obtained by this.
- the outline (solid line part) of the first through hole 12 is separated from the outline (broken line part) of the second through hole 14. That is, the outline of the first through hole 12 does not intersect with the outline of the second through hole 14. According to such a configuration, it is possible to more reliably prevent foreign matter from entering between the inner block 3 and the second shell 13.
- the second shell 13 is fixed to the first shell 11 by inserting the key 5 into the keyway 2. Therefore, the second shell 13 rotates in synchronization with the first shell 11. It is not essential for the present invention that the first shell 11 and the second shell 13 rotate in synchronization, and the second shell 13 may be able to rotate with respect to the first shell 11. However, if both rotate synchronously, the relative positional relationship between the first through hole 12 and the second through hole 14 is kept constant, so that the entry of foreign matter into the second through hole 14 is more effective. Can be prevented.
- the second shell 13 may be fixed to the first shell 11 by fixing means other than the key 5. Examples of such fixing means include screws and bolts.
- the fixing means may be formed by engaging a part of the second shell 13 and a part of the first shell 11.
- the second shell 13 has an outer peripheral surface 13p that is in close contact with the inner peripheral surface 11q of the first shell 11. According to such a configuration, foreign matter can be prevented from entering between the first shell 11 and the second shell 13. Further, since the heat transfer from the first shell 11 to the second shell 13 is also good, the cooling efficiency of the substrate 21 is increased.
- the second shell 13 further has a recess 50 (a counterbore) formed at a position facing the first through hole 12.
- the second through hole 14 is opened in the recess 50. According to such a configuration, entry of foreign matter into the second through hole 14 can be more effectively prevented.
- the inner block 3 is a member that is prohibited from rotating in synchronization with the substrate 21.
- the inner block 3 is fixed to the support 10.
- the support 10 is fixed to the vacuum chamber 22, for example. That is, the position and posture of the inner block 3 are fixed with respect to the vacuum chamber 22.
- the manifold 4 is a space defined by the inner block 3 inside the first shell 11 so as to hold the gas introduced from the outside of the vacuum chamber 22.
- the manifold 4 is formed so as to guide the gas toward the plurality of first through holes 12 within the range of the holding angle.
- the manifold 4 has a relatively wide dimension with respect to the radial direction of the first shell 11. Therefore, the gas pressure between the first shell 11 and the substrate 21 is maintained at a relatively high pressure.
- a plurality of manifolds 4 are formed along the width direction WD of the shells 11 and 13.
- a second through hole 14 is opened toward each of the plurality of manifolds 4. The gas is supplied to each of the plurality of manifolds 4 through the gas flow path 7.
- the manifold 4 is set within the range of the holding angle. As a result, the gas released from the first through hole 12 through the manifold 4 is easily confined between the first shell 11 and the substrate 21. More desirably, the manifold 4 is set in a range that is more than the pitch A (see FIG. 3C) from both sides of the holding angle range. This makes it easier to confine the gas released from the first through hole 12 through the manifold 4 between the first shell 11 and the substrate 21.
- the manifold 4 is formed, for example, by hollowing out a part of the inner block 3, and the second through hole 14, the recess 50, the first through hole 12, and the gas flow path 7 formed inside the support body 10. Communicate.
- the conductance of the gas path from the gas flow path 7 to the first through hole 12 can be set independently by changing the shape of each manifold 4 as necessary. Further, the ejection angle of the first through hole 12 can be adjusted independently in the width direction of the substrate 21. This makes it possible to change the gas cooling intensity in the width direction of the substrate 21.
- the thermal load received by the central portion of the substrate 21 in the width direction is often larger than the thermal load received by the end portions of the substrate 21 in the width direction. This is because even if the thickness of the thin film is uniform, the thermal load caused by radiant heat is larger in the vicinity of the central portion of the substrate 21 than in the end portion. In such a case, the amount of gas ejected from each manifold 4 of the blow roller 6 via the first through hole 12 and the second through hole 14 is relatively large at the center of the substrate 21, and the end of the substrate 21 is The conductance design of the plurality of manifolds 4 may be performed so that the number of the manifolds is relatively small. In this way, the cooling strength can be changed according to the thermal load received by the substrate 21. The temperature distribution in the width direction of the substrate 21 can be reduced, and thermal deflection of the substrate 21 can be reduced.
- “within the holding angle range” includes a case where one end or both ends of the holding angle range coincide with one end or both ends of the range of the manifold 4 in the circumferential direction of the first shell 11. .
- “match” does not mean perfect match. In terms of the rotation angle of the first shell 11, for example, even if the manifold 4 protrudes from the holding angle range by about 2 to 3 degrees, this is only an error, and one or both ends of the holding angle range. Is coincident with one end or both ends of the range of the manifold 4.
- the gap 15 is also a space formed inside the first shell 11, and gas is directed toward the plurality of first through holes 12 outside the range of the holding angle (specifically, outside the range of the specific angle). It is formed to guide. Specifically, a gap 15 is formed between the second shell 13 and the inner block 3. With respect to the radial direction of the first shell 11, the gap portion 15 has a relatively narrow dimension.
- the width of the gap 15 in the radial direction is, for example, in the range of 30 to 200 ⁇ m. If the width of the gap portion 15 is appropriately adjusted, the amount of gas leaking to the outside of the blow roller 6 through the gap portion 15 can be reduced, so that the degree of vacuum can be prevented from deteriorating. Further, contact between the second shell 13 and the inner block 3 based on processing accuracy of each member, deformation due to thermal expansion, and the like can be avoided, and abnormal rotation and damage to the blow roller 6 can be prevented.
- the “holding angle” is defined by an angle ⁇ of a contact portion between the first shell 11 and the substrate 21 around the rotation axis O of the first shell 11.
- the size of the hugging angle is not particularly limited. For example, when the holding angle is within a range of 30 to 180 degrees (or 45 to 120 degrees), even when the outer diameter of the first shell 11 is small to some extent, the substrate 21 can be smoothed without generating excessive bending stress. Can be transported.
- the transport system 36A is disposed on the downstream side of the blow roller 6 along the transport direction of the substrate and the first roller disposed on the upstream side of the blow roller 6 along the transport direction of the substrate 21.
- the holding angle is defined by the relative positional relationship among the first roller, the blow roller 6 and the second roller.
- the “first roller” is the winding core roller 23 or the conveyance roller 24.
- the “second roller” is the conveyance roller 24 or the winding core roller 26.
- the manifold 4 is formed so as to guide the gas toward the plurality of first through holes 12 within a specific angle range around the rotation axis O of the first shell 11.
- the transport system 36A can be constructed so that the “specific angle” falls within the range of the holding angle. That is, the “specific angle” is an angle equal to or smaller than the holding angle.
- a transport system 36A is constructed inside the vacuum chamber 22.
- the substrate 21 is transported from the unwinding position (winding roller 23) of the transport system 36A to the winding position (winding roller 26).
- the material is evaporated from the film forming source 19 toward the opening 31 provided in the transport path of the transport system 36 ⁇ / b> A so that the material is applied to the substrate 21.
- the relative relationship between the first roller (core roller 23), the blow roller 6 and the second roller (conveyance roller 24) so that the “specific angle” is within the range of the holding angle. Set a specific positional relationship.
- the holding angle defined by the angle ⁇ is two line segments obtained by connecting the centers of the two second through holes 14 adjacent to each other in the circumferential direction and the rotation axis O. It is larger than the angle ⁇ formed. According to this relationship, at least one of the plurality of second through holes 14 can always face the manifold 4.
- the range (angle range) of the manifold 4 in the circumferential direction is defined so that the manifold 4 faces the plurality of second through holes 14 only within the range of the holding angle. According to this configuration, the gas pressure between the first shell 11 and the substrate 21 can be easily maintained at a high pressure.
- the inner block 3 has an arcuate outer peripheral surface 3p outside the range of the holding angle.
- a gap 15 is formed between the arc-shaped outer peripheral surface 3p of the inner block 3 and the inner peripheral surface 13q of the second shell 13. According to this configuration, it is easy to keep the width of the gap 15 constant. That is, the width of the gap 15 may be constant. A portion having a constant width can be regarded as the gap portion 15, and other portions can be regarded as the manifold 4.
- the first through holes 12 are formed at equal intervals along the width direction WD of the first shell 11.
- the second through holes 14 are formed at equal intervals along the width direction WD of the second shell 13.
- the uniformity of the cooling capability in the width direction can be ensured.
- the first through holes 12 are formed at equal intervals along the circumferential direction LD.
- the second through holes 14 are formed at equal intervals along the circumferential direction LD.
- the recess 50 has a longitudinal direction parallel to the width direction WD.
- One first through hole 12 faces one recess 50 and one second through hole 14 opens. That is, the pair of the first through hole 12 and the second through hole 14 are arranged along the width direction WD. According to such a positional relationship, even if the first shell 11 and the second shell 13 can be rotated relatively, it is difficult for foreign matter to enter the second through hole 14.
- the longitudinal direction of the recess 50 may be parallel to the circumferential direction LD.
- the shape of the recess 50 is not particularly limited.
- the recess 50 may gradually become deeper from the position where the second through hole 14 is opened toward the position facing the first through hole 12.
- An imaginary straight line passing through the central axis of the first through-hole 12 and the central axis of the second through-hole 14 and perpendicularly intersecting these central axes is defined.
- the recess 50 may have a V-shaped, semi-circular, semi-elliptical, rectangular or other contour.
- the width direction WD is the width direction of the first shell 11 and the second shell 13 and means a direction parallel to the rotation axis O.
- the circumferential direction LD is the circumferential direction of the outer peripheral surface 11 p of the first shell 11 and also the circumferential direction of the outer peripheral surface 13 p of the second shell 13.
- the arrangement of the first through holes 12 and the arrangement of the second through holes 14 are not particularly limited.
- the plurality of first through holes 12 includes (i) a first group G 1 provided along the circumferential direction LD at a predetermined position in the width direction WD parallel to the rotation axis O; (Ii) A second group G 2 provided along the circumferential direction LD at a position adjacent to the predetermined position is configured.
- the plurality of first through holes 12 belonging to the first group G 1 and the plurality of first through holes 12 belonging to the second group G 2 form an alternating arrangement. That is, the first through holes 12 are located on the lattice points of the staggered lattice in the development view of the first shell 11. According to such an arrangement of the first through holes 12, more uniform cooling is possible.
- the support 10 is a member that supports the inner block 3, and includes a gas flow path 7 (gas introduction port) for introducing gas into the manifold 4 from the outside of the vacuum chamber 22, And a refrigerant flow path 46 for flowing a refrigerant for cooling the support 10.
- the gas flow path 7 may be configured by a single flow path that can supply only one type of gas to the manifold 4, or may be configured by a plurality of flow paths so that a plurality of types of gas can be supplied to the manifold 4. It may be. Further, when a plurality of manifolds 4 are formed, the gas flow path 7 is configured so that the gas supply amount to one manifold 4 and the gas supply amount to another manifold can be made different from each other. Also good.
- the gas fills the manifold 4 formed in the inner block 3 through the gas supply pipe 32 and the gas flow path 7.
- the gas is led preferentially to the second through hole 14 facing the manifold 4 among the plurality of second through holes 14, led to the first through hole 12 through the recess 50, and from the first through hole 12 to the substrate 21. Erupts toward the back of the.
- the cooling means is not limited to water, and a liquid or gaseous refrigerant can be used. Water is supplied to the water channel 46 from the outside of the vacuum chamber 22. The water that has flowed through the water flow path 46 is returned to the outside of the vacuum chamber 22.
- the support 10 and the inner block 3 are composed of separate parts.
- a part of the inner block 3 may protrude from the first shell 11, and the protruding part may serve as the support 10. That is, the support 10 and the inner block 3 may be formed integrally.
- a gas leakage reducing member 37 facing the outer peripheral surface 11p of the first shell 11 may be provided. Thereby, the leakage of the gas outside the range of the holding angle can be suppressed.
- the gas leakage reducing member 37 is, for example, a curved plate disposed at a position in the range of 50 to 300 ⁇ m from the first shell 11 outside the holding angle range.
- the gas leakage reducing member 37 has, for example, an arc shape along the outer peripheral surface 11p of the first shell 11.
- a gas leakage reducing member 37 can be provided at a position facing the outer peripheral surface 11p of the first shell 11 and outside the holding angle range.
- the holding plate 51 is disposed on both end surfaces of the first shell 11 and the second shell 13 so as to close a slight gap between the first shell 11 and the second shell 13.
- the temperature of the first shell 11 is higher than the temperature of the second shell 13.
- the gap between the first shell 11 and the second shell 13 is slightly enlarged due to thermal expansion, and gas may leak.
- the holding plate 51 has an effect of preventing gas leakage due to the enlargement of the gap.
- the material of the first shell 11 has a thermal expansion coefficient smaller than that of the material of the second shell 13, the following effects are obtained. That is, even when the temperature of the first shell 11 is higher than the temperature of the second shell 13 when the blow roller 6 is used, it is possible to suppress an increase in the gap between the first shell 11 and the second shell 13.
- the first shell 11 is made of SUS430 and the second shell 13 is made of SUS304.
- the linear expansion coefficient of SUS430 is 1.04 ⁇ 10 ⁇ 5 / ° C. with an average value of 0 to 100 ° C.
- the linear expansion coefficient of SUS304 is 1.73 ⁇ 10 ⁇ 5 / ° C. with an average value of 0 to 100 ° C.
- the inner diameter of the first shell 11 and the outer diameter of the second shell 13 are about 100 mm, and the first shell 11 and the second shell 13 are fitted together by an intermediate fit.
- the inner diameter of the first shell 11 changes from 100.035 mm to 100.063 mm, and the outer diameter of the second shell 13 changes. Varies from 99.965 mm to 99.994 mm.
- the width of the gap between the first shell 11 and the second shell 13 changes from 0.07 mm to 0.069 mm. That is, the gap hardly expands.
- the second shell 13 is closely attached and fixed to the first shell 11. Specifically, the second shell 13 is incorporated into the first shell 11 with a predetermined fitting accuracy (for example, intermediate fit), and the key 5 is used to prevent the second shell 13 from rotating with respect to the first shell 11. It is fixed.
- the outer diameter of the first shell 11 is in the range of 40 to 1000 mm, for example. When the outer diameter of the first shell 11 is in such a range, sufficient cooling capacity can be obtained while suppressing the equipment cost. Moreover, the grinding process for forming the inner peripheral surface 11q of the first shell 11 is facilitated.
- the length of the first shell 11 in the axial direction is, for example, in the range of 100 to 800 mm.
- the axial length of the first shell 11 should be longer than the width of the substrate 21 in order for the substrate 21 to travel stably.
- the accuracy of the gap between the first shell 11 and the second shell 13 can be appropriately maintained.
- the thickness of the first shell 11 in the region where the first through hole 12 is formed is, for example, in the range of 2 to 15 mm. When the thickness of the first shell 11 is in such a range, the deformation of the first shell 11 can be prevented. Moreover, the process for forming the 1st through-hole 12 is also easy.
- the diameter of the first through hole 12 is appropriately set according to the cooling condition of the substrate 21, the degree of vacuum, and the like.
- the diameter of the first through hole 12 is in the range of 0.5 to 3 mm, for example.
- gas leakage can be minimized.
- the process for forming the 1st through-hole 12 becomes easy.
- the pitch A of the first through holes 12 represents the interval between the two first through holes 12 adjacent to each other in the circumferential direction LD.
- the pitch B of the first through holes 12 represents the interval between two first through holes 12 adjacent to each other in the width direction WD.
- the pitch A and the pitch B are also set as appropriate according to the cooling conditions of the substrate 21, the degree of vacuum, and the like.
- the pitch A is, for example, in the range of 10 to 50 mm.
- the pitch A may be in the range of 5 to 30 degrees, for example, in terms of the rotation angle of the first shell 11. If the pitch A is adjusted appropriately, the width of the pressure fluctuation due to the rotation angle of the first shell 11 can be reduced, and the uniformity of the cooling capacity is improved.
- the pitch B is, for example, in the range of 10 to 200 mm.
- the pitch B does not have to be constant along the width direction WD. That is, the first through holes 12 do not have to be arranged at regular intervals along the width direction WD.
- the pitch B can be appropriately adjusted according to the temperature of the substrate 21 and the cooling state. When the pitch B is adjusted appropriately, the uniformity of the cooling capacity in the width direction WD increases.
- the number of first through holes 12 is an appropriate number, it is possible to prevent an increase in processing cost.
- the outer diameter of the second shell 13 is specified by the inner diameter of the first shell 11 and the fitting accuracy.
- the inner diameter of the first shell 11 can be H7
- the outer diameter of the second shell 13 can be h7.
- “H7” and “h7” mean dimensional tolerances defined in Japanese Industrial Standards JIS B 0401 (1999).
- the length of the second shell 13 in the axial direction is determined according to the length of the first shell 11 in the axial direction.
- the length of the second shell 13 in the axial direction is, for example, in the range of 100 to 800 mm.
- the thickness of the second shell 13 in the region where the second through hole 14 is formed is, for example, in the range of 5 to 15 mm.
- the depth of the recess 50 is, for example, in the range of 2 to 5 mm.
- the depth of the part is in the range of 5 to 10 mm, for example.
- the width of the recess 50 is preferably larger than the diameter of the first through hole 12. In this way, it is easy to optimize the conductance of the gas flow path.
- the width of the recess 50 is in the range of 3 to 5 mm, for example.
- the diameter of the second through hole 14 is appropriately set according to the cooling condition of the substrate 21, the degree of vacuum, and the like.
- the diameter of the second through hole 14 is, for example, in the range of 0.1 to 3 mm.
- the second through hole 14 may have a diameter smaller than the diameter of the first through hole 12. In this way, even if a foreign substance passes through the first through hole 12, it can be stopped by the second through hole 14. As a result, the probability of foreign matter entering between the second shell 13 and the inner block 3 can be further reduced.
- the pitch C of the second through holes 14 represents the interval between the two second through holes 14 adjacent to each other in the circumferential direction LD.
- the pitch B of the second through holes 14 represents the interval between the two second through holes 14 adjacent to each other in the width direction WD.
- the pitch C and the pitch D are formed to match the pitch A and the pitch B of the first through hole 12. That is, each pitch is determined so that the central axis of the first through hole 12 and the central axis of the second through hole 14 do not exist on the same straight line.
- the concave portion 50 of the second shell 13 exists on the extension line of the central axis of the first through hole 12.
- the first through hole 12 may have a diameter that is reduced from the outer peripheral side of the first shell 11 toward the central side.
- the diameter of the 1st through-hole 12 may be changing continuously, as shown to FIG. 7B.
- the diameter of the 1st through-hole 12 may be changing in steps.
- the 1st through-hole 12 may have a part with which the diameter is changing continuously, and a part with a constant diameter.
- the second through hole 14 may have a diameter that decreases from the outer peripheral side of the second shell 13 toward the center side.
- the diameter of the second through hole 14 may be continuously changed as shown in FIGS. 7D and 7E. Further, the diameter of the second through hole 14 may be changed in stages. Furthermore, as shown in FIG. 7C, the second through hole 14 may have a portion where the diameter continuously changes and a portion where the diameter is constant.
- the diameter of the second through hole 14 on the outer peripheral side of the second shell 13 may be smaller than the diameter of the first through hole 12 on the center side of the first shell 11. According to such a relationship, it is possible to prevent foreign matters that are smaller than the diameter of the first through hole 12 and larger than the diameter of the second through hole 14 from entering the gap portion 15.
- the recess 50 includes a first portion 50a located on an extension line of the central axis of the first through hole 12 and a second portion 50b in which the second through hole 14 is opened. You may go out.
- the depth of the first portion 50a is deeper than the depth of the second portion 50b. According to such a configuration, foreign matter is likely to be captured by the first portion 50 a, so that the foreign matter is unlikely to reach the second through hole 14 even if it can pass through the first through hole 12.
- the first through hole 12, the recessed portion 50, and the second through hole 14 are formed between the manifold 4 and the gap portion 15 as the first shell 11 and the second shell 13 rotate. Move in opposition.
- the conductance of the gas path from the gas flow path 7 to the first through hole 12 is much larger when passing through the manifold 4 than when passing through the gap 15.
- the amount of gas that passes outwardly through the first through hole 12 when facing the manifold 4 is such that the first through hole 12 faces the gap 15. More than the amount of gas passing through. Accordingly, since the gas can be efficiently discharged from the first through hole 12 in the range of the holding angle where the substrate 21 contacts the blow roller 6, the gas pressure between the first shell 11 and the substrate 21 is increased. be able to.
- Leakage from between the outer peripheral surface 11p of the first shell 11 and the substrate 21 is caused by making the average pressure between the outer peripheral surface 11p of the first shell 11 and the substrate 21 lower than the atmospheric pressure when the gas is introduced.
- the amount of gas to be released can be reduced. Thereby, the load of the exhaust pump 35 can be reduced.
- the buoyancy due to the average pressure between the outer peripheral surface 11p of the first shell 11 and the substrate 21 is higher than the vertical drag force of the substrate 21 on the blow roller 6 due to the transport tension of the substrate 21. small. Therefore, the change of the space
- substrate 21 is 100 micrometers or less with the presence or absence of gas introduction, for example. That is, the substrate 21 can be prevented from being lifted, and the substrate 21 can be efficiently cooled.
- blow roller 6 of the present embodiment even if foreign matter enters the first through hole 12, it can be prevented from entering the manifold 4 and the gap portion 15. Thereby, the rubbing damage
- the blow roller 6 ⁇ / b> B according to the first modification has a wide manifold 44. Only one manifold 44 is formed in the inner block 3. According to such a configuration, the cost of the inner block 3 can be reduced.
- the width of the manifold 44 (the length in the direction parallel to the rotation axis O) is smoothly supplied to each of the plurality of second through holes 14 arranged in the direction parallel to the rotation axis O (width direction WD). It is adjusted so that it can. Specifically, the width of the manifold 44 is larger than the distance between the two second through holes 14 located at both ends in the width direction WD.
- the blow roller 6 ⁇ / b> C according to Modification 2 includes a plurality of gas flow path 7 systems.
- the gas flow path 7 includes a first gas flow path 7a that communicates with all of the plurality of manifolds 4, and a second gas flow path 7b that communicates with the manifold 4 formed inside the manifold 4 at the end.
- the second gas flow path 7b communicates with at least one of the plurality of manifolds 4 formed inside the two manifolds 4 positioned at both ends in the width direction among the plurality of manifolds 4. Yes.
- the amount of gas introduced into the manifold 4 in the width direction of the substrate 21 can be changed, and the cooling strength can be changed according to the thermal load received by the substrate 21.
- the type of gas in the first gas channel 7a can be different from the type of gas in the second gas channel 7b.
- the thermal load is strong at the center of the substrate 21, particularly when a metal foil substrate is used, the center of the substrate 21 tends to stretch.
- the central portion of the substrate 21 is slightly lifted from the blow roller 6C.
- argon gas is used for the first gas flow path 7a
- helium gas is used for the second gas flow path 7b.
- the blow roller 6D according to the modification 3 includes an inner block 33 composed of a plurality of divided blocks 3a.
- the divided blocks 3a are arranged along the rotation axis O.
- a manifold 4 is formed in each divided block 3a. According to such a configuration, the structure of the blow roller 6D can be changed according to desired cooling conditions. That is, the cooling condition can be easily changed by rearranging the divided blocks 3a.
- the second shell 13 has a groove-like recess 52 extending parallel to the circumferential direction LD.
- the recess 52 may be formed around the entire periphery of the second shell 13.
- the recesses 52 are formed in a plurality of rows along the width direction WD.
- the interval between the adjacent recesses 52 may be constant or different.
- a plurality of first through holes 12 face one recess 52.
- a plurality of second through holes 14 are open to one recess 52. According to such a configuration, it is possible to avoid complicated processing for forming the concave portion 52 of the second shell 13 by cutting, and thus it is possible to reduce the manufacturing cost of the blow roller 6E.
- the second shell 13 has a groove-like recess 54 extending in parallel to the width direction WD.
- the recess 54 may be formed in the second shell 13 from one end to the other end in the width direction WD.
- the recesses 54 are formed in a plurality of rows along the circumferential direction LD. The interval between the adjacent recesses 54 is constant.
- a plurality of first through holes 12 face one recess 54.
- a plurality of second through holes 14 are open to one recess 54. According to such a configuration, the same effect as the blow roller 6E according to Modification 4 can be obtained.
- the second shell 13 has a groove-like recess 54 extending in parallel to the width direction WD.
- the structure of the recess 54 is as described with reference to FIGS. 12A and 12B.
- the second shell 13 has a plurality of second through holes 14 formed in only one row along the circumferential direction LD. Only one manifold 4 is formed in the inner block 3.
- a plurality of first through holes 12 face one recess 54.
- one second through hole 14 is open to one recess 54. According to such a configuration, the manufacturing cost of the blow roller 6G can be further reduced.
- the second shell 13 has a groove-like recess 56 extending in parallel with the width direction WD.
- the recess 56 may be formed in the second shell 13 from one end to the other end in the width direction WD.
- the recesses 56 are formed in a plurality of rows along the circumferential direction LD. The interval between the adjacent recesses 56 is constant.
- the second shell 13 has a plurality of second through holes 14 formed in only one row along the circumferential direction LD. Only one manifold 4 is formed in the inner block 3.
- a plurality of first through holes 12 face one recess 56.
- one second through hole 14 is open to one recess 56.
- the concave portion 56 includes a first portion 56a located on an extension line of the central axis of the first through hole 12, and a second portion 56b in which the second through hole 14 is opened.
- the depth of the first portion 56a is deeper than the depth of the second portion 56b. According to such a configuration, foreign matter is easily captured by the first portion 56 a, so that the foreign matter is unlikely to reach the second through hole 14 even if it can pass through the first through hole 12.
- the second shell 13 has a groove-shaped recess 58 extending in parallel with the width direction WD and the circumferential direction LD.
- the recess 58 includes a first portion 58a extending in parallel with the circumferential direction LD and a second portion 58b extending in parallel with the width direction WD.
- the depth of the first portion 58a is deeper than the depth of the second portion 58b. According to such a configuration, foreign matter is easily captured by the first portion 58 a, so that the foreign matter is unlikely to reach the second through hole 14 even if it can pass through the first through hole 12.
- a wide manifold 44 is formed in the inner block 3.
- the manifold 44 is as described with reference to FIG.
- the plurality of first through holes 12 face one first portion 58a.
- the plurality of first through holes 12 face one second portion 58b.
- a plurality of second through holes 14 may be opened in one second portion 58b.
- one second through hole 14 may be opened in one second portion 58b.
- the shape of the recesses and the number of the second through holes 14 in the second shell 13 are not particularly limited.
- the shape and number of manifolds 4 can be determined according to the number of second through holes 14.
- the advantageous configurations of the blow rolls 6, 6B, 6C, 6D, 6E, 6F, 6G, 6H and 6I described herein can be combined with each other.
- Examplementation condition 1 For example, in the blow roller 6 shown in FIG. 3A, the outer diameter of the first shell 11 is 110 mm, the width of the first shell 11 is 120 mm, and the thickness of the first shell 11 is 6.5 mm (the inner diameter of the first shell is 97H7).
- the diameter of the first through-holes 12 is 1 mm, the pitch A is 20 degrees, and the pitch B is 19 mm to form a 5-row configuration.
- the outer diameter of the second shell 13 is 97h7, the thickness of the second shell 13 is 6 mm, the diameter of the second through-hole 14 is 0.7 mm, the pitch C is 20 degrees, and the pitch D is 19 mm.
- the depth of the recess 50 is 2 mm, the width is 3 mm, and the length is 13 mm. However, on the extended line of the central axis of the first through hole 12, the diameter of the recess 50 is 3 mm and the depth is 4 mm.
- the central axis of the first through hole 12 and the central axis of the second through hole 14 are shifted by 11.8 degrees.
- the distance between the second shell 13 and the inner block 3 in the gap 15 is 100 ⁇ m.
- the manifold 4 of the inner block 3 is divided into five, and helium gas is introduced into the manifold 4 at both ends as a gas from the gas flow path 7 in a total of 20 sccm (Standard Cubic Centimeter per Minute), and a total of 53 sccm is introduced into the three manifolds 4 in the center.
- the gas cooling ability equivalent to the case where helium gas is introduced so that the entire vacuum chamber 22 becomes 100 Pa without introducing gas from the gas flow path 7 can be obtained.
- the heat transfer coefficient can be calculated by measuring the temperature of the substrate 21 traveling on the surface of the blow roller 6 with a thermocouple or the like and changing the movement time and the temperature of the substrate 21.
- the heat transfer coefficient by gas cooling is, for example, 0.003 W / cm 2 / K, although it depends on the type of the substrate 21.
- a helium gas introduction amount of about 680 sccm is required.
- the blow roller 6 can reduce the gas introduction amount to about 1/9. A relatively small amount of gas is flowed to the end of the substrate 21, and a relatively large amount of gas is flowed to the center of the substrate 21. Thereby, the cooling in the center part of the board
- Examplementation condition 2 Using the thin film manufacturing apparatus 20B shown in FIG. 2, a negative electrode for a lithium ion secondary battery can be manufactured under the following conditions.
- a silicon multilayer thin film is formed on both sides of the current collector to a thickness of 8 ⁇ m by vacuum deposition.
- the vacuum tank 22 having two oil diffusion pumps with a diameter of 14 inches as the exhaust pump 35 and having a volume of 0.4 m 3 is evacuated to 0.002 Pa, and then silicon as a film forming material is dissolved. Silicon is dissolved by using a 270 ° deflection electron beam evaporation source (deposition source 19).
- the molten silicon is irradiated with an electron beam having an acceleration voltage of ⁇ 10 kV and an emission current of 520 to 700 mA, and the generated vapor is directed along the can 27 to the traveling substrate 21.
- a metal mask (opening length is 100 mm each) (not shown) is arranged at a position of about 2 mm from the substrate 21 so that the film forming width of the silicon thin film becomes 85 mm.
- the transport system 36B is configured to allow the substrate 21 to reciprocate.
- a silicon thin film having a film thickness of about 0.5 ⁇ m is formed on both surfaces of the substrate 21 by one run. By repeating the film formation 16 times while reciprocating, a silicon thin film of about 8 ⁇ m can be formed.
- each layer on both surfaces of the substrate 21 is performed, for example, at an average emission current of 600 mA, a substrate transfer speed of 2 m / min, and an average film formation speed of 80 nm / sec.
- the blow roller 6 is disposed in the conveyance path after the silicon thin film is formed on one surface (first surface) of the substrate 21 and before film formation on the other surface (second surface) is performed.
- the outer diameter of the first shell 11 is 120 mm
- the width of the first shell 11 is 120 mm
- the thickness of the first shell 11 is 4 mm
- the diameter of the first through holes 12 is 1 mm
- the pitch A is 20 degrees.
- the pitch B is 15 mm and the structure is 5 rows.
- the outer diameter of the second shell 13 is 112h7
- the thickness of the second shell 13 is 6 mm
- the diameter of the second through-hole 14 is 0.7 mm
- the pitch C is 20 degrees
- the pitch D is 15 mm.
- the depth of the recess 50 is 2 mm, the width is 3 mm, and the length is 14.6 mm. However, on the extended line of the central axis of the first through hole 12, the diameter of the recess 50 is 3 mm and the depth is 4 mm. The central axis of the first through hole 12 and the central axis of the second through hole 14 are shifted by 11.8 degrees. The distance between the second shell 13 and the inner block 3 in the gap 15 is 80 ⁇ m. A total of 80 sccm of helium gas is introduced into the manifold 4 as gas from the gas flow path 7.
- the temperature of the substrate 21 at the start of film formation on each surface of the substrate 21 can be made substantially the same.
- the quality of the thin film can be made equal, and the warpage of the substrate 21 after film formation due to the difference in thermal expansion coefficient or the like is reduced. be able to.
- the maximum temperature reached by the substrate 21 can be lowered, and deterioration of the substrate 21 can be prevented.
- the deterioration of the copper foil due to a temperature rise can be evaluated by, for example, a change in mechanical property values by a tensile test or the like. it can.
- the thermally deteriorated copper foil exhibits phenomena such as an increase in elongation with respect to a tensile load and a decrease in breaking strength. These characteristic deteriorations lead to deformation and breakage of the electrode plate because the silicon thin film used for the lithium secondary battery electrode plate expands during lithium occlusion.
- the blow roller 6 is arranged on a path from each film formation position to the winding core roller 26.
- substrate 21 at the time of winding can be made into normal temperature.
- generation of wrinkles due to thermal deformation of the substrate 21 at the time of winding is prevented, and the phenomenon of tightening due to the shrinkage of the substrate 21 after winding is prevented. be able to.
- the outer diameter of the first shell 11 is 80 mm, the width of the first shell 11 is 120 mm, the thickness of the first shell 11 is 4 mm (the inner diameter of the first shell is 72H7), The diameter is 1 mm, the pitch A is 15 degrees, and the pitch B is 15 mm.
- the outer diameter of the second shell 13 is 72h7, the thickness of the second shell 13 is 6 mm, the diameter of the second through-hole 14 is 0.7 mm, the pitch C is 15 degrees, and the pitch D is 15 mm.
- the depth of the recess 50 is 2 mm, the width is 3 mm, and the length is 7.4 mm.
- the diameter of the recess 50 is 3 mm and the depth is 4 mm.
- the central axis of the first through hole 12 and the central axis of the second through hole 14 are shifted by 11.8 degrees.
- the interval between the second shell 13 and the inner block 3 in the gap 15 is 50 ⁇ m.
- the manifold 4 of the inner block 3 is divided into five, and argon gas is introduced as a gas from the gas flow path 7 into the manifold 4 at both ends in a total of 14 sccm and into the three manifolds 4 at the center in a total of 36 sccm.
- the gas can be used efficiently, deterioration of the degree of vacuum during cooling can be prevented.
- the substrate transport roller can be prevented from being locked, and thus damage to the substrate can be suppressed.
- other gas cooling methods can be combined with the technology disclosed in the present specification, an increase in the size of equipment such as an exhaust pump can be suppressed, and a low-cost thin film manufacturing apparatus can be realized.
- the technique disclosed in the present specification can be suitably employed in a thin film manufacturing apparatus that requires high-speed and stable film formation.
- the technology disclosed in the present specification can be employed in the manufacture of devices and functional thin films.
- the device include an electrode plate for a lithium ion secondary battery, an electrode plate for an electrochemical capacitor, a capacitor, a solar cell, and various sensors.
- the functional thin film include a transparent electrode film, a decorative film, a magnetic tape, a gas barrier film, various optical films, and a hard protective film.
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Abstract
Description
真空中で基板を搬送する機能及び前記基板を冷却するためのガスを真空中で前記基板に向けて供給する機能を有する基板搬送ローラであって、
前記基板を支持するための円筒形の外周面と、前記外周面の周方向に沿って設けられた、前記ガスの供給経路としての複数の第1貫通孔とを有し、前記基板と同期して回転できる第1シェルと、
前記第1シェルの内部に配置され、前記基板と同期して回転することが禁止された内ブロックと、
外部から導入された前記ガスを保持するように前記第1シェルの内部において前記内ブロックによって規定された空間であって、前記第1シェルの回転軸を中心として特定の角度の範囲内で複数の前記第1貫通孔に向けて前記ガスを導くように形成されており、前記第1シェルの径方向に関して相対的に広い寸法を有するマニホールドと、
前記第1シェルの内部に形成された空間であって、前記特定の角度の範囲外で複数の前記第1貫通孔に向けて前記ガスを導くように形成されており、前記径方向に関して相対的に狭い寸法を有する隙間部と、
前記第1シェルと前記内ブロックとの間に配置され、前記マニホールドから複数の前記第1貫通孔に前記ガスを導く第2貫通孔を有する第2シェルと、
を備え、
前記第1貫通孔の中心軸が前記第2貫通孔の中心軸からオフセットしている、基板搬送ローラを提供する。
真空中で基板を搬送する機能及び前記基板を冷却するためのガスを真空中で前記基板に向けて供給する機能を有する基板搬送ローラであって、
前記基板を支持するための円筒形の外周面と、前記外周面の周方向に沿って設けられた、前記ガスの供給経路としての複数の第1貫通孔とを有し、前記基板と同期して回転できる第1シェルと、
前記第1シェルの内部に配置され、前記基板と同期して回転することが禁止された内ブロックと、
外部から導入された前記ガスを保持するように前記第1シェルの内部において前記内ブロックによって規定された空間であって、前記第1シェルの回転軸を中心として特定の角度の範囲内で複数の前記第1貫通孔に向けて前記ガスを導くように形成されており、前記第1シェルの径方向に関して相対的に広い寸法を有するマニホールドと、
前記第1シェルの内部に形成された空間であって、前記特定の角度の範囲外で複数の前記第1貫通孔に向けて前記ガスを導くように形成されており、前記径方向に関して相対的に狭い寸法を有する隙間部と、
前記第1シェルと前記内ブロックとの間に配置され、前記マニホールドから複数の前記第1貫通孔に前記ガスを導く第2貫通孔を有する第2シェルと、
を備え、
前記第1貫通孔の中心軸が前記第2貫通孔の中心軸からオフセットしている、基板搬送ローラを提供する。
真空槽と、
第1~第13態様のいずれか1つの基板搬送ローラを有し、長尺の基板を巻き出し位置から巻き取り位置へと搬送するように前記真空槽内に配置された搬送系と、
前記搬送系の搬送経路に設けられた開口部と、
前記開口部で前記基板に材料を付与するための成膜源と、
を備えた、薄膜の製造装置を提供する。
第1~第13態様のいずれか1つの基板搬送ローラを用い、真空槽内に長尺の基板の搬送系を構築する工程と、
前記搬送系の巻き出し位置から巻き取り位置へと長尺の基板を搬送する工程と、
前記基板に材料が付与されるように、前記搬送系の搬送経路に設けられた開口部に向けて成膜源から材料を蒸発させる工程と、
を含む、薄膜の製造方法を提供する。
図8に示すように、変形例1に係るブローローラ6Bは、幅広のマニホールド44を有している。マニホールド44は、内ブロック3に1つのみ形成されている。このような構成によれば、内ブロック3のコストを低減できる。マニホールド44の幅(回転軸Oに平行な方向の長さ)は、回転軸Oに平行な方向(幅方向WD)に配列している複数の第2貫通孔14のそれぞれに円滑にガスを供給できるように調節されている。具体的には、マニホールド44の幅は、幅方向WDにおいて両端に位置している2つの第2貫通孔14の距離よりも大きい。
図9に示すように、変形例2に係るブローローラ6Cは、ガス流路7の系統を複数備えている。ガス流路7は、複数のマニホールド4の全てと連通している第1ガス流路7aと、端部のマニホールド4よりも内側に形成されたマニホールド4と連通している第2ガス流路7bとを含む。詳細には、第2ガス流路7bは、複数のマニホールド4のうち、幅方向において両端に位置している2つのマニホールド4よりも内側に形成された複数のマニホールド4の少なくとも1つと連通している。これによって、基板21の幅方向でマニホールド4に導入されるガス量を変え、基板21が受ける熱負荷に応じて冷却強度を変化させることができる。また、第1ガス流路7aのガスの種類を第2ガス流路7bのガスの種類と異ならせることもできる。例えば、基板21の中央部で熱負荷が強い場合、特に金属箔基板を用いた場合等には、基板21の中央部が伸びやすい。これによって、基板21の中央部が、若干、ブローローラ6Cから浮き上がりやすい。このような場合、例えば第1ガス流路7aにアルゴンガスを用い、第2ガス流路7bにヘリウムガスを用いる。ヘリウムガスは、高価ではあるが、分子衝突が起きにくいのでブローローラ6Cと基板21との間隔が広くても冷却能力が得やすい。これにより、ブローローラ6Cから基板21が多少浮き上がっていたとしても、基板21の中央部付近を重点的に冷却することができる。
図10に示すように、変形例3に係るブローローラ6Dは、複数の分割ブロック3aで構成された内ブロック33を備えている。分割ブロック3aは、回転軸Oに沿って配列している。各分割ブロック3aにマニホールド4が形成されている。このような構成によれば、所望の冷却条件に応じてブローローラ6Dの構造を変更することができる。すなわち、分割ブロック3aの組み替えによって、冷却条件を簡単に変更することができる。
図11A及び図11Bに示すように、変形例4に係るブローローラ6Eにおいて、第2シェル13は、周方向LDに平行に延びている溝状の凹部52を有する。凹部52は、第2シェル13の全周囲に形成されていてもよい。凹部52は、幅方向WDに沿って複数の列で形成されている。隣り合う凹部52同士の間隔は一定であってもよいし、異なっていてもよい。1つの凹部52に対して、複数の第1貫通孔12が向かい合っている。同様に、1つの凹部52に対して、複数の第2貫通孔14が開口している。このような構成によれば、第2シェル13の凹部52を切削によって形成するための加工が複雑になることを回避できるので、ブローローラ6Eの製作費用を削減できる。
図12A及び図12Bに示すように、変形例5に係るブローローラ6Fにおいて、第2シェル13は、幅方向WDに平行に延びている溝状の凹部54を有する。凹部54は、幅方向WDの一端から他端にわたって第2シェル13に形成されていてもよい。凹部54は、周方向LDに沿って複数の列で形成されている。隣り合う凹部54の間隔は一定である。1つの凹部54に対して、複数の第1貫通孔12が向かい合っている。同様に、1つの凹部54に対して、複数の第2貫通孔14が開口している。このような構成によれば、変形例4に係るブローローラ6Eと同じ効果が得られる。
図13A及び図13Bに示すように、変形例6に係るブローローラ6Gにおいて、第2シェル13は、幅方向WDに平行に延びている溝状の凹部54を有する。凹部54の構造は図12A及び図12Bを参照して説明した通りである。第2シェル13には、周方向LDに沿って、複数の第2貫通孔14が1列のみ形成されている。内ブロック3には、マニホールド4が1つのみ形成されている。1つの凹部54に対して、複数の第1貫通孔12が向かい合っている。他方、1つの凹部54に対して、1つの第2貫通孔14が開口している。このような構成によれば、ブローローラ6Gの製作費用をさらに削減できる。
図14A及び図14Bに示すように、変形例7に係るブローローラ6Hにおいて、第2シェル13は、幅方向WDに平行に延びている溝状の凹部56を有する。凹部56は、幅方向WDの一端から他端にわたって第2シェル13に形成されていてもよい。凹部56は、周方向LDに沿って複数の列で形成されている。隣り合う凹部56の間隔は一定である。第2シェル13には、周方向LDに沿って、複数の第2貫通孔14が1列のみ形成されている。内ブロック3には、マニホールド4が1つのみ形成されている。1つの凹部56に対して、複数の第1貫通孔12が向かい合っている。他方、1つの凹部56に対して、1つの第2貫通孔14が開口している。
図15A及び図15Bに示すように、変形例8に係るブローローラ6Iにおいて、第2シェル13は、幅方向WD及び周方向LDに平行に延びている溝状の凹部58を有する。凹部58は、詳細には、周方向LDに平行に延びている第1部分58aと、幅方向WDに平行に延びている第2部分58bとを含む。第1部分58aの深さは、第2部分58bの深さよりも深い。このような構成によれば、第1部分58aに異物が捕獲されやすいので、異物は、第1貫通孔12を通過できたとしても、第2貫通孔14に到達しにくい。内ブロック3には、幅広のマニホールド44が形成されている。このマニホールド44は、図8を参照して説明した通りである。図15B及び図15Cに示すように、1つの第1部分58aに対して、複数の第1貫通孔12が向かい合っている。1つの第2部分58bに対して、複数の第1貫通孔12が向かい合っている。図15Bに示すように、1つの第2部分58bに複数の第2貫通孔14が開口していてもよい。図15Cに示すように、1つの第2部分58bに1つの第2貫通孔14が開口していてもよい。
例えば、図3Aに示すブローローラ6において、第1シェル11の外径を110mm、第1シェル11の幅を120mm、第1シェル11の肉厚を6.5mm(第1シェルの内径は97H7)、第1貫通孔12の直径を1mm、ピッチAを20度、ピッチBを19mmで5列構成とする。第2シェル13の外径を97h7、第2シェル13の肉厚を6mm、第2貫通孔14の直径を0.7mm、ピッチCを20度、ピッチDを19mmで5列構成とする。凹部50の深さを2mm、幅を3mm、長さを13mmとする。ただし、第1貫通孔12の中心軸の延長線上において、凹部50の直径を3mm、深さを4mmとする。第1貫通孔12の中心軸と第2貫通孔14の中心軸とを11.8度ずらす。隙間部15における第2シェル13と内ブロック3との間隔を100μmとする。内ブロック3のマニホールド4を5分割し、ガス流路7からのガスとしてヘリウムガスを両端のマニホールド4に合計20sccm(Standard Cubic Centimeter per Minute)、中央部の3つのマニホールド4に合計53sccm導入する。この場合、ガス流路7からのガス導入をせずに、真空槽22の全体が100Paとなるようにヘリウムガスを導入した場合と同等のガス冷却能力が得られる。熱伝達係数は、ブローローラ6の表面を走行中の基板21の温度を熱電対等で測定し、移動時間と基板21の温度の変化とから算出できる。ガス冷却による熱伝達係数は基板21の種類にもよるが、例えば0.003W/cm2/Kである。
図2に示す薄膜の製造装置20Bを用い、以下の条件により、リチウムイオン二次電池用の負極を製造することができる。
Claims (15)
- 真空中で基板を搬送する機能及び前記基板を冷却するためのガスを真空中で前記基板に向けて供給する機能を有する基板搬送ローラであって、
前記基板を支持するための円筒形の外周面と、前記外周面の周方向に沿って設けられた、前記ガスの供給経路としての複数の第1貫通孔とを有し、前記基板と同期して回転できる第1シェルと、
前記第1シェルの内部に配置され、前記基板と同期して回転することが禁止された内ブロックと、
外部から導入された前記ガスを保持するように前記第1シェルの内部において前記内ブロックによって規定された空間であって、前記第1シェルの回転軸を中心として特定の角度の範囲内で複数の前記第1貫通孔に向けて前記ガスを導くように形成されており、前記第1シェルの径方向に関して相対的に広い寸法を有するマニホールドと、
前記第1シェルの内部に形成された空間であって、前記特定の角度の範囲外で複数の前記第1貫通孔に向けて前記ガスを導くように形成されており、前記径方向に関して相対的に狭い寸法を有する隙間部と、
前記第1シェルと前記内ブロックとの間に配置され、前記マニホールドから複数の前記第1貫通孔に前記ガスを導く第2貫通孔を有する第2シェルと、
を備え、
前記第1貫通孔の中心軸が前記第2貫通孔の中心軸からオフセットしている、基板搬送ローラ。 - 前記第1シェルが前記第2シェルと同期して回転する、請求項1に記載の基板搬送ローラ。
- 前記第2シェルが、前記第1シェルの内周面に密着している外周面を有し、
前記隙間部が前記第2シェルと前記内ブロックとの間に形成されている、請求項2に記載の基板搬送ローラ。 - 前記第1シェル及び前記第2シェルを展開し、さらに、前記第1シェルの表面に平行な平面に前記第1シェル及び前記第2シェルを投影することによって得られた投影図において、前記第1貫通孔の輪郭が前記第2貫通孔の輪郭から離れている、請求項1に記載の基板搬送ローラ。
- 前記第2シェルは、前記第1貫通孔に向かい合う位置に形成された凹部をさらに有し、
前記凹部に前記第2貫通孔が開口している、請求項1に記載の基板搬送ローラ。 - 1つの前記凹部に対して、複数の前記第1貫通孔が向かい合っている、請求項5に記載の基板搬送ローラ。
- 前記第2シェルが、複数の前記第2貫通孔を有し、
1つの前記凹部に対して、複数の前記第2貫通孔が開口している、請求項5に記載の基板搬送ローラ。 - 前記内ブロックを支持している支持体をさらに備え、
前記支持体は、前記外部から前記マニホールドに前記ガスを導入するためのガス流路を有する、請求項1に記載の基板搬送ローラ。 - 前記第1貫通孔が、前記第1シェルの外周側から中心側に向かって縮小している直径を有する、請求項1に記載の基板搬送ローラ。
- 前記第2貫通孔が、前記第2シェルの外周側から中心側に向かって縮小している直径を有する、請求項1に記載の基板搬送ローラ。
- 前記凹部が、前記第1貫通孔の中心軸の延長線上に位置している第1部分と、前記第2貫通孔が開口している第2部分とを含み、
前記第1部分の深さが、前記第2部分の深さよりも深い、請求項5に記載の基板搬送ローラ。 - 前記第2シェルの外周側における前記第2貫通孔の直径が、前記第1シェルの中心側における前記第1貫通孔の直径よりも小さい、請求項1に記載の基板搬送ローラ。
- 複数の前記第1貫通孔は、(i)前記回転軸に平行な幅方向の所定位置において前記周方向に沿って設けられた第1グループと、(ii)前記所定位置に隣接した位置において前記周方向に沿って設けられた第2グループと、を構成しており、
前記第1グループに属する複数の前記第1貫通孔と、前記第2グループに属する複数の前記第1貫通孔とが、互い違いの配列を形成している、請求項1に記載の基板搬送ローラ。 - 真空槽と、
請求項1に記載の基板搬送ローラを有し、長尺の基板を巻き出し位置から巻き取り位置へと搬送するように前記真空槽内に配置された搬送系と、
前記搬送系の搬送経路に設けられた開口部と、
前記開口部で前記基板に材料を付与するための成膜源と、
を備えた、薄膜の製造装置。 - 請求項1に記載の基板搬送ローラを用い、真空槽内に長尺の基板の搬送系を構築する工程と、
前記搬送系の巻き出し位置から巻き取り位置へと長尺の基板を搬送する工程と、
前記基板に材料が付与されるように、前記搬送系の搬送経路に設けられた開口部に向けて成膜源から材料を蒸発させる工程と、
を含む、薄膜の製造方法。
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