The present invention relates to a band processing plant with the features of preamble of claim 1.
Processing plants of this type are mainly designed for coating flexible band substrates, such as, for example, plastics foils, magnetic tapes, films, etc. in vacuum (for example, by sputtering, i.e. target atomization, eventually reinforced by magnetic fields, evaporation, PVD or CVD processes), as well as for additional processing methods, such as pre-processing/cleaning/drying/surface activation/polymerization, etc. It is required, in such cases, to introduce into the plant the band substrates, supplied in the form of bales or foils, which are being placed upon a bearing axle, so that during the coating process, the band substrate may be unrolled from this bale.
Beyond/downstream from the coating chamber(s), another axle is provided with a take-up reel, upon which the coated band substrate is again being winded.
Basically, such a band coating plant may be split up into modules (unrolling, coating and take-up modules).
On known plants, both axes or cylinders, bilaterally mounted for unrolling and winding up said band substrate, are assembled on a common frame-like base, which offers the advantage that they are in a reciprocal constant and firm positional relationship. When both axes or cylinders are disposed on both sides of the coating module, during the exchange of spools it can be avoided, by means of separate measures, to ventilate also the coating chamber(s) operating in vacuum.
It should be aimed not to ventilate the coating chamber, operating in vacuum, at each exchange of the substrate bale, i.e. when removing from a band substrate a newly rolled up bale, which has just been coated.
It is, therefore, already known to mount air-lock valves between individual modules. The volume which is again to be ventilated, is thus clearly reduced, since only the admittance and the removal stations, respectively, are being ventilated and the effective coating chamber may permanently remain in an evacuated condition. Evidently, in case of need, the entire plant may be ventilated.
DE 197 35 603 C1 describes a continuous vacuum coating plant with different subsequently disposed coating chambers, where inside each coating chamber a roller frame is provided, comprising by-pass rolls, band measuring rolls and cooling rolls. The roller frames may be adjusted in such a fashion in their respective coating chamber that the rolls and cylinders of the subsequent chambers may be reciprocally adjusted. The magnetron sources of said coating chambers are assembled independently from the roller frames, so that they may both be adjusted and exchanged without having to alter the position of the cylinders.
The band substrate to be processed will be introduced from an unwinding chamber into the coating chambers and downwards from the latter will be introduced into a roll up or winding up, chamber, and between the unrolling and roll up chambers and the coating chambers, vacuum valves are provided, which will not be covered in detail.
DE 101 57 186 C1 describes another continuous vacuum coating unit from a subdivision into unroll, coating and roll up chambers, between which air-lock or band valves are provided. The spool shafts, provided inside the evacuable unroll and roll up chambers are provided on said roller frames, with are fixed independently from each other and may be separately moved out of the plant. On the contrary, the cylinders in the processing module are disposed on a common roller frame. For all roller frames, common fixation or deposition points are provided at the separating walls, between the roll up chambers and the processing module. Reciprocal displacements of roller frames during operation should be avoided during operation by providing, during operation, a maximum pressure differential of 50 Pa between roll up chambers and processing module. Said processing module may be closed with a separate cover, provided, on its turn, with access openings.
WO 99/50 472 describes a vacuum band coating plant, which comprises a loading respectively discharge station with corresponding winding and dewinding reels arranged in a common chamber and at least a separately provided reaction chamber (coating module). The band substrate passes through cylinder air-locks between loading and discharge stations, said cylinder air locks acting as pressure stages. In one version, it may pass between two cylinders rolling upon each other, and, in another version, it may pass between a cylinder and a fixed sealing block. These cylinder air-locks may be opened, in order to introduce, for example, a new band substrate. For this purpose, either one of the cylinders may be folded out, its rotary axis being mounted foldable around an axis of rotation, or the sealing block will be removed from the cylinder.
In one embodiment of this known plant, all cylinders and valves, with drives, are provided on a common basis, which may be introduced in a housing. The gaps between basis and housing may be closed vacuum-tight by means of circumferential seals. Nevertheless, in view of their spatial orders, especially in the area of said air-lock valves, not all these seals may be applied on plane sealing surfaces. Also in this plant, in view of the existence of said air-lock valves, the band spools may be exchanged, without having to ventilate said processing chamber.
The object of the invention consists in providing another processing plant, enabling a change of unwinding and roll up spools, without having to ventilate the entire plant, i.e. the evacuating processing section.
According to the invention, this task will be solved with the features of claim 1. The features of the dependent claims indicate advantageous embodiments of the invention.
According to the invention, roll up stations and processing stations are provided inside or upon different bases, which may be moved relatively to each other. The basis of the processing plant is a firm section of the plant housing, which also surrounds the winding up sections during operational conditions.
Winding up sections are provided in a structure, comprising its common basis and open towards the processing module, being moveable vis-à-vis the plant housing, and they may be sealed by valves against the actual processing plant (or processing module).
Preferably, the entire basis is a closed plate, forming a wall section of said structure. In an especially convenient embodiment, this basic plate of the winding up stations, during operational conditions, simultaneously forms a wall section of the housing of the overall plant. In addition, it forms a wall of a chamber, formed inside the structure itself, said chamber featuring essentially a closed format.
From the outside, the winding up stations may be accessed through separate openings of said plant housing, which during operational conditions may be tightly closed. To these openings correspond openings in the wall of the structure, bearing the winding up stations. After closing said valves and venting winding up stations, a quick exchange will thus be feasible of the band spools, without having to ventilate the entire plant and without having to extract the winding up stations from the plant housing.
In an especially preferred embodiment, the structure, or also the plant housing, comprises a sealing, surrounding the loading and/or unloading opening. This seal is advantageously operable through fluid pressure, so that it features a sealing and an inactive position. In the latter, the simple extraction and introduction of said winding up sections is feasible without exerting efforts upon said seal. In the sealed position, the respective opening may be used to change loading actions, without having to ventilate the entire plant. Advantageously, this seal may be applied against a plane internal wall of said housing and may be disposed at this wall, in order to be applied, in case of need, against a flange section of said structure.
Advantageously, the air-lock valves will be provided with an opening for traversing said band substrate and a body to close this opening, and the closed position of said body may also be used to retain said band substrate during the exchange of substrate spools or supports.
Other details and advantages of the object of the present invention may be seen in the drawing of an exemplary embodiment and based on the subsequent, detailed description.
The figures show, in simplified fashion:
At the bottom area of said housing 1, a processing set B is only indicated, which, for example, may comprise at least one sputtering cathode. All by-pass and cooling cylinders are part of the rolling up system and are assembled on said structure 12. While
The trajectory of intersection of
The band substrate to be coated will be conducted from an unrolling cylinder 17 towards the coating cylinder underneath and through processing station B. The latter may evidently also comprise different sputtering cathodes. Subsequently, said substrate is being conducted upwards, to be received by winding up cylinder (as can also be seen in
On the upper, inner wall 6 (above winding up station 10) of housing 1, at least one opening 7 is provided, normally closed with a chamber cover 8. This is provided at the border of inner wall 6, surrounding opening 7, being safely sealed by means of a circumferential seal 9. As can be seen in
From the same, plane inner wall 6, is also formed the inner opening (on the chamber side) of a pump socket, not shown here.
Advantageously, said chamber cover 8 may be opened with winding up stations in the introduced position.
Support 12 bears a plate-like base 11, closed and pertaining to winding up station 10. It also comprises an upper opening 13, as well as an “active” seal 14, circumferentially surrounding it and preferentially inflatable with fluid pressure, a closed (resistance) mounting plate 15, two sockets 16 for substrate spools or bales, firmly disposed at base 11 and at the mounting plate 15, and lastly a substrate spool 17, rotably applied upon said sockets 16. The coating cylinder, provided underneath, is mounted on specific mounting sockets, independently from the unwinding cylinder.
Seal 14 is provided on a flange surrounding opening 13; the fluid pressure connections, required for operation, are not being shown here to simplify the view. Preferentially, said seal will be provided inside a surrounding groove of said flange, in order to be safely protected against mechanical damages, when not being actively used.
Base 11 and mounting plate 15 comprise a closed side wall of structure 12. The upper section of structure 12 forms, as a whole, a chamber essentially closed, surrounding said substrate spool 17, said chamber offering access only through opening 13.
Underneath said counter-plate 15,
Opening 13 in structure 12 of said winding up station 10 is sufficiently large, being thus positioned that it overlaps opening 7 of inner wall 6 with the chamber cover 8. Consequently, inflatable seal 12 also surrounds said opening 7.
Differently from the representation, seal 14 could basically also be provided at said inner wall 6 of housing 1, on the same spot, in order to be juxtaposed at the flange surrounding opening 13 of structure 12, in inflated condition.
Before commissioning processing plant and after correct fixation of structure 12 inside housing 1, the latter will be evacuated by air suction by means of pumps (not shown). Seal 14 may be applied against the plane inner wall 6 of housing 1 (sealed position), applying pressure thereupon over said fluid connections, not shown.
Nevertheless, it does not have to be constantly “activated” during normal operation of said processing plant, since housing 1 encompasses both the winding up stations as well as the processing station, which are therefore simultaneously evacuated. Seal 14 will only be effectively required when it is intended to ventilate winding up station 10 independently from the remaining housing 1, i.e. when it is intended to open the chamber cover(s) 8.
During the moving phases of winding up station 10 relative to housing 1—i.e. not in operational status of plant, for example during maintenance or cleaning operations, which cannot be simply accomplished after opening a chamber cover 8—or with completely evacuated housing 1, (including winding up chamber 10), said seal 14 will be distended (its inner pressure will be neutralized) or it will be exposed to lower sub-pressure. As a consequence, it will be largely retracted into its seat groove (retracted position), where it is protected against friction and damages.
As can be seen in the comparison of
Underneath said substrate spool 17, a band substrate 17S is being conducted from unwinding station 10 in structure 12, in a downward direction in processing module B. The corresponding opening of winding up chamber or of winding up station 10, may be locked by an air-lock valve 18 vis-à-vis said housing 1 and processing station B. Said air-lock valve is provided inside said moveable structure 12; during opening and extraction of structure 12, it will consequently be removed from housing 1.
The air-lock valve 18 renders it possible to exchange the substrate supports- or spools 17, existing inside winding up stations 10, without having to ventilate housing 1 altogether. As will be later described, in its closed position, said air-lock valve 18 locks without any gaps said processing station B against winding up station 10. It is designed as a static valve, which, during plant operation, offers a relatively large free transversal section, through which said band substrate may pass free of contact.
In this view, it may again be well recognized how the flexible substrate 17S which may be removed from substrate spool 17, is transferred from structure 12 into processing module B, provided underneath the winding up station, by means of (at least) one by-pass cylinder and through air-lock valve 18, also indicated only schematically. Said air-lock valve is firmly mounted on structure 12.
Structure 12 of winding up stations 10 forms, thus, as already mentioned, a chamber which is surrounded by the common basis 11 and mounting plate 15 (
This chamber may be accessed both externally through opening 7, closed by chamber cover 8 and circumferentially sealed by seal 14, also when it is in operational condition inside housing 1 of said processing plant.
Also opposed to winding up station 10 according to
It can be provided that the winding up stations 10 may be opened and ventilated independently from each other, i.e. whilst one unit is being ventilated, the other may remain evacuated (in this case, the separating wall, shown in
This second winding up station 10, corresponding to the principle of
During operation, said air-lock valve 18 is capable to safely eliminate considerable pressure differentials, for example between atmospheric pressure and vacuum.
It may, however, also be opening, on one side, in order to enable free passage and substrate flux, and, on the other side, in order to render feasible traversing i.e. introduction of new substrates, when the previously processed, flexible substrate has been completely removed from the plant. Evidently, the opening width of valve will be sized in a measure adjusted to the sizes (especially the width) of the substrate to be processed.
Lastly, by means of the air-lock valve 18, terminal sections of the finished band sub-strate may be retained, in order to fix new band substrates in known fashion on said terminal sections and subsequently—instead of complex manual introduction procedures—to introduce and traverse the new band substrate by means of the “old” remaining segment.
It would, thus, basically be possible to design the air-lock valves in the same fashion as outlined in WO-A1 99/50472 above. However, other embodiments may be used. An exemplary embodiment will be schematically explained, based on
Consequently, said air-lock valves 18 are quite essential for the above described option to exchange substrate spools without complete extraction of unwinding station(s) 10. They render feasible, in closed condition, to open said chamber cover 8, without similarly ventilating processing module B then evacuated.
Additionally, both air-lock valves 18 may be joined here to compose one built unit 18′, although evidently for each extracting and introducing substrate section, a specific/independent valve function has to be provided.
It can be seen that the face inside the housing, turned toward the valve body 21, where opening 19 ends, is formed in such a fashion that substrate 17S between border section of said opening (which simultaneously may serve or be formed as a sealing surface 22) and the valve body 21 transferred in the closed position, may be mounted in paralyzed condition without being exclusively bent in the process. Surface 22, directed towards the sealing edge, is applied obliquely towards the band substrate plane. Also sealing surface 22, which may be closed by valve body 21, eventually with substrate 17S in an intermediate position, is designed in such a fashion at opening 19 (eventually using soft and elastic materials as edge or surface seals) that a satisfactory sealing effect remains insured, independently whether valve body 21 is being forcibly applied separately or jointly with substrate.
Preferably, said air-lock valve 18 will be provided in structure 12 or 12′ as separate module. This applies especially also for the fusion into one valve block, shown in
As already outlined above, this embodiment enables, on one side, with substrate still remaining inside the plant, to ventilate said winding up stations 10 or 10′, whilst processing module B remains evacuated, and, on the other side, after exchange of substrate spools, the new band substrate may be introduced by means of the remaining band section, fixed in the valves. For this purpose, the initial section of the new band substrate will be glued with the remaining band section.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP04/05618 | 5/25/2004 | WO | 11/14/2006 |