Patent Application
20070013642
This application claims priority under 35 U.S.C. § 119 of Korean Patent Application No. 2005-0063233, filed Jul. 13, 2005, the disclosure of which is incorporated herein by reference in its entirety.
(1) Field of the Invention
The present invention relates to a system for automatically transferring substrates of flat panel displays between the processing stations of a flat panel display manufacturing line.
(2) Description of the Related Art
Currently, flat panel displays, such as liquid crystal displays (“LCDs”), organic light emitting diode displays and the like, are used in a wide variety of display applications.
A flat panel display is produced by conveying a glass substrate to processing equipment located at the respective stations of a flat panel display manufacturing line using a transferring system and then performing one or more manufacturing processes on the substrate at each of those locations.
A conventional flat panel display transferring system includes a “cassette,” a “stoker,” a “conveyor,” and an “indexer.” In the conventional system, the cassette, in which a plurality of substrates is loaded, is stored in the stoker, and the stoker with the stored cassettes is carried to the entrance of processing equipment using the conveyor. The indexer is then used to move the substrates in the cassette into and out of the processing equipment at the respective entrances of the processing stations.
However, conventional panel display conveying systems that use a cassette, stoker, conveyor, and indexer necessarily involve the presence of redundant in-process components, and can thus incur substantial costs in maintaining the redundant in-process components in the manufacturing line.
In accordance with the exemplary embodiments described herein, the present invention overcomes the above problems by the provision of apparatus and methods for transferring flat panel displays within a flat panel display manufacturing line that minimizes both component transfer time and the number of in-process components present in the line.
According to one exemplary embodiment thereof, a flat panel display transferring system comprises a transfer device that transfers a container in which a substrate is loaded, and a container loading and unloading (“LU”) device that loads and unloads the container to and from the display processing equipment located at the respective processing stations of the line. The transfer device can include a fixed member, such as a track, mounted on floor of the facility and a plurality of moveable members, such as wheeled trucks, or carriages, that move along the fixed member.
The fixed member preferably includes a center track forming a closed loop and one or more looping branch tracks that branch out from the center track and are connected to the entrances of the respective display processing stations of the manufacturing line. In one exemplary embodiment, each of the center and branch tracks includes elongated rails and a plurality of coils disposed between the rails. For example, the tracks can comprise two parallel rails that are spaced apart from each other at a predetermined distance, with the plurality of coils being arranged at predetermined intervals along the length of the rails. Each of the rails preferably includes extensions that extend upwardly from the outer edges thereof.
The carriages include a container support bed, a permanent magnet mounted under the bed and disposed in a spaced apart, overlying relationship with the coils, and wheels mounted under the bed and adapted to engage and roll along the rails. Preferably, auxiliary wheels that contact the upstanding extensions of the rails are also included below the bed. The coils of the track and the permanent magnet of the carriages define a linear motor that controllably propels the carriages along the tracks.
The substrate transfer container includes a lattice-shaped base frame, a plurality of upstanding support frames mounted on the base frame, a plurality of first support pins mounted on the first support frame that support the substrate, and a container cover that covers the substrate. A base cover that closes the space between lattice beams of the base frame is also included. A side surface of the container cover is openable and closable, e.g., by means of a hinged closure, or door. The container can also include additional substrate support frames and pins mounted on top of each other for simultaneous transportation of a plurality substrates in a stacked fashion.
The container LU device includes an enclosure having an interior space and a vertical transfer device, or elevator, mounted in the enclosure. A fan unit having an air cleaning filter is mounted on the frame and arranged to blow filtered air into the enclosure to prevent the entrance of contaminants. The elevator operates to move the container in a vertical direction within the enclosure. The enclosure of the LU device includes an opening at a side surface thereof, the container LU device is mounted adjacent to each of the entrances of the processing stations, and a track of the system is laid out to pass through a lower side of the container LU device.
In one exemplary embodiment, a substrate loading and unloading (“LU”) robot is mounted between the container LU device and the respective entrances of each of the processing stations. The LU robot includes a support portion, a horizontal and vertical transfer portion mounted on the support portion, and a transfer arm mounted on the horizontal and vertical transfer portion. A substrate loaded on the transfer arm of the robot is transferred from the transfer container to the equipment of a processing station through the opening of the enclosure of the LU device, and the transfer arm of the robot is arranged to move between the LU device and the processing equipment by way of the shortest path.
In an alternative embodiment, a transfer conveyor is mounted between the LU device and the processing equipment, and a container conveyor is mounted in the transfer container such that the two conveyors are located in line with each other and at the same vertical level.
In accordance with an exemplary method of the present invention, a method of transferring a flat panel display includes positioning a carriage, which moves along a track and on which a transfer container is loaded, below a container LU device, raising the container with an elevator mounted in the container LU device, and transferring a display substrate contained in the container into the equipment located at a display processing station. When the substrate has been transferred into the processing equipment, the empty carriage moves away from the station along the track.
The method further includes lowering the transfer container with the elevator to load the container onto a second carriage, and moving the second carriage away from the station along the track.
The method can further include opening a side surface of the container, introducing the transfer arm of a LU robot located between the container device and the processing equipment into the transfer container through an opening of the container LU device, loading the substrate onto the transfer arm, moving the transfer arm into the processing station, and placing the substrate in the processing equipment of the station.
In an alternative embodiment of the method, the transfer container can include a container conveyer upon which the substrate is loaded, and transferring of the substrate contained in the container can include opening a side surface of the transfer container, positioning a transfer conveyor mounted between the container LU device and the processing equipment and positioned in line with and at the same vertical level as the container conveyer, and simultaneously driving the transfer conveyor and the container conveyor, thereby carrying the substrate loaded on the container conveyor into the equipment of a processing.
According to another aspect of the present invention, a method is provided for transferring a flat panel display between the processing stations of a manufacturing line, including positioning a first moveable member that moves along a fixed member and on which a transfer container is loaded below a container LU device, and transferring a substrate contained in the transfer container into the equipment of a processing station by a substrate LU robot located between the container LU device and the station.
The transferring of the substrate contained in the transfer container can include opening a side surface of the transfer container, introducing a transfer arm of a substrate LU robot located between the container LU device and the processing station into the transfer container through an opening of the container LU device, loading the substrate onto the transfer arm, moving the transfer arm into the processing station, and placing the substrate in the processing equipment of the station.
In an alternative embodiment of the method, the transferring of the substrate contained in the transfer container may include opening a side surface of the transfer container, simultaneously driving a transfer conveyor mounted between the container LU device and the processing equipment and a container conveyor mounted in the transfer container, and carrying the substrate loaded on the container conveyor into the processing equipment. Preferably, the transfer conveyor and the container conveyor are located in line with each other and at the same vertical level.
A better understanding of the above and many other features and advantages of the panel display substrate transfer system of the present invention may be obtained from the detailed description of the exemplary embodiments thereof below, particularly if such consideration is made in conjunction with the several views of the appended drawings, wherein like reference numerals are used to identify like elements illustrated in one or more of the figures thereof.
As illustrated in
The transfer devices 100, 140, and 200 comprise tracks 100 and 200 mounted on the floor of the production facility, and a plurality of carriages 140 that move along the tracks 100 and 200 between the processing stations 500. As illustrated in
Each of carriages 140 includes a horizontal support bed 141, a permanent magnet 150 mounted below the bed in a spaced apart, overlying relationship with the coils 130, and wheels 161 and 162 respectively mounted on opposite sides of and below the bed and arranged to engage and roll along the rails. In the particular exemplary embodiment illustrated, the bed includes a pair of horizontal slats 145, which help support the bed and prevent it from being warped or wracked by heavy loads.
As illustrated in
As those of skill in the art will appreciate, the permanent magnet 150 of the carriage 140 and the coils 130 of the tracks 100 and 200 define a linear motor that is capable of moving the carriage along the tracks stably, at a relatively high speed of about 200 m/minute. Thus, the carriages 140 do not need to be connected with a power supply unit, and further, do not require any mechanical element for the delivery of motive power. Accordingly, the carriages can be light in weight and programmed to move rapidly and with precision to any position along the tracks 100 and 200.
The center track 100 and the branch tracks 200 stably guide the carriages 140 in a predetermined path such that the carriages 140 cannot separate from the tracks during movement along either straight or curved portions thereof, and further, the carriages 140 can efficiently and stably change their direction of travel at junctions between the center and branch tracks 100 and 200.
In a preferred embodiment, the tracks 100 and 200 are connected to a communication device, such as a serial communication device or a field bus, such that operational information, including speed and position of the carriages 140, can be monitored and controlled by a computer. Additionally, an interlocking device can be provided to prevent collisions between the carriages 140 during operation of the system. Addition fail-safe devices can be provided in the system such that a malfunction of one carriage 140 or the driving coil 130 associated with it can stop driving of the other carriages 140 and/or associated driver coils 130.
It should be further understood that, in the case of a conventional panel display transfer system of the type that uses a stoker, when the stoker malfunctions, the entire manufacturing process must be halted. However, in the transfer system of the present invention, if one carriage 140 is out of order, movement of the other carriages 140 within the system can be quickly resumed simply by removing only the malfunctioning carriage 140 from the system.
Further, since the tracks 100 and 200 of the system can be easily laid, maintained and even waterproofed, if desired, the transfer system can be readily deployed in a processing line that uses moisture-aversive chemical agents, such as a cleaning line.
Additionally, it may be seen that an increase in production capacity is readily obtainable simply by increasing the number of carriages 140, and moreover, the travel path of the carriages 140 can be more rapidly and easily expanded as compared with a conventional conveyor system.
The base frame 11 of the container 10 is provided with a lattice shape such that it is light in weight but strong so as to prevent it from being warped or wracked by the weight of a large substrate 5. Base plugs, or covers 12, are mounted in the openings between the lattice beams to prevent foreign material from entering the container through the openings.
The first support pins 14 are mounted as a group and are spaced apart from each other at a selected intervals. Accordingly, an arm of a substrate loading and unloading (“LU”) robot 60 of the type described below can enter into the spaces between the first support pins 14, lift up a substrate 5 supported on the pins, and carry it out of the transfer container 10.
Additional support frames and support pins (not illustrated) can be mounted above the first support frame 13 and pins 14 at selected vertical intervals, to support additional substrates 5 in the container in a stacked fashion. Thus, it should be understood that, although the particular transfer container 10 illustrated in the figures is shown as carrying only one substrate 5, the container is can easily be configured to carry a plurality of substrates simultaneously. Preferably, the side surface of the container cover 15 is openable and closed by way of a hinged closure to prevent contamination of the substrates by foreign matter during transit. Accordingly, when the closure of the side surface of the container cover 15 is opened, the substrate LU robot 60 can either carry a substrate 5 out of the transfer container 10 or transfer a substrate from the processing station 500 into the container. Alternatively, the upper surface of the container cover 15 can incorporate a closure (not illustrated) that opens to enable the substrate LU robot 60 to carry the substrate 5 from the transfer container 10 to the processing equipment 500.
In the exemplary embodiment illustrated, the base frame 11 of the transfer container 10 is made of an aluminum (Al) alloy or carbon fiber reinforced plastic (CFRP), the base cover(s) 12 and the container cover 15 are made of polycarbonate, and the first support frame 13 and the first support pins 14 are made of carbon fiber reinforced plastics. Accordingly, the resulting transfer container 10 is both light in weight, strong and rigid, is easily maintained, and is difficult to deform. Since the transfer container 10 in which the substrate 5 is loaded moves to the respective processing stations 500 by way of the carriages 140, the container can either transfer or store the substrate 5 while maintaining the high level of cleanliness required of a flat panel display manufacturing facility. Furthermore, the transfer container 10 can prevent the substrate 5 from being scratched or damaged when it is being transferred.
The elevator 54 is mounted outside of the rails 110 and 120 that pass through the enclosure 51, and is adapted to raise a transfer container 10 up from or lower it down onto a carriage 140 disposed on the rails, i.e., to transfer the transfer container 10 in a vertical direction relative to the rails and the carriage 140.
As illustrated in
In addition, unlike a substrate LU robot 60 used in a conventional transfer system that includes a stoker, since the substrate LU robot 60 of the present embodiment needs to move only a small amount in the Z direction to be able to lift and place the substrate 5, the amount of movement of the substrate 5 in the Z direction is relatively much smaller, and hence, the time required to load or unload the substrate 5 is relatively shorter.
In operation, the transfer arm 63 of the substrate LU robot 60 enters into the transfer container 10 through the opening 53 in the side of the enclosure 51, loads the substrate 5 thereon, then translates to the entrance of the processing station 500 and thereby carries the substrate 5 into the processing equipment located therein.
As illustrated in
FIGS. 5 to 8 sequentially illustrate a method of loading or unloading a panel display substrate 5 to or from a substrate processing station 500 using the container LU device 300 and the substrate LU robot 60 of the first exemplary embodiment of the system of the present invention.
As illustrated in
Next, as illustrated in
Then, as illustrated sequentially in
When the substrate 5 is placed in the processing station 500, the empty carriage 140 can then depart by way of the rails 110, 120 of the tracks 100, 200 to a next destination thereon. A second empty carriage 140 can then be moved along the tracks and positioned below the container LU device 300. The empty transfer container 10 is then lowered by the elevator 54 and loaded onto the second carriage. The second carriage 140 can then depart, carrying the empty transfer container 10 to a next destination along the tracks.
As will be appreciated, when it is desired to move a processed substrate 5 from a processing station 500 to another destination, e.g., a second processing station 500 in the manufacturing line, the foregoing procedure is simply effected in the reverse order.
Since the carriages 140 can move continuously and independently of each other along the rails 110, 120 except when a transfer container 10 is being loaded or unloaded to or from them, transfer delays do not occur in the system and substrate transfer time is substantially reduced.
Furthermore, since a plurality of substrates 5 can be transferred simultaneously using the same transfer container 10 and linear motor system, the number of in-process components can be significantly reduced. In addition, the cumulative substrate transfer time is substantially reduced by the more direct connection between the manufacturing process stations afforded by the system.
As will be appreciated, in a factory manufacturing line, the in-process components are those that are being manufactured on the line at a given point in time. In general, since the same components are being successively processed in the factory, the in-process components exist in each stage of processing. Accordingly, the amount of the in-process components in each processing stage is generally calculated as inventory. In the system of the present invention, since the substrates 5 are successively transferred without the use of a conventional stoker, the transfer system operates without interruption or the need to provide redundant in-process components, and thus, the number of in-process components, i.e., excess inventory, is reduced.
A second exemplary embodiment of a system for transferring flat panel displays between the processing stations of a panel display manufacturing line in accordance with the present invention is illustrated in the schematic cross-sectional elevation view
As illustrated in
As may be seen by a comparison of
A third exemplary embodiment of a system for transferring flat panel display substrates between the processing stations of a panel display manufacturing line in accordance with the present invention is illustrated in the schematic cross-sectional elevation view
The third embodiment of
In a method of transferring flat panel displays using the transfer system of
When positioned in the container LU device 300, the transfer container 10 is raised by the elevator 54, and the substrate 5 contained in the transfer container 10 is then transferred into the equipment of the processing station 500 by the transfer conveyor 71. That is, the hinged closure 15a in the side surface of the transfer container 10 is first opened. The transfer conveyor 71 mounted between the container LU device 300 and the processing station 500 and the container conveyor 72 mounted in the transfer container 10 are positioned in line with each other and at the same vertical level. The transfer conveyor 71 and the container conveyor 72 are simultaneously driven and the substrate 5 is thereby carried from the container conveyor 72 to the transfer conveyor 71, which then carries the substrate into the processing station 500.
When the substrate 5 contained in the transfer container 10 is transferred into the processing station 500, the empty carriage 140 moves away to a next destination along the tracks.
Next, as illustrated in
According to the present invention, since a transfer device and a container LU device driven by a linear motor are used, the time to transfer a substrate between processing stations can be reduced substantially. Furthermore, since the substrates are transferred in protective transfer containers, the substrates are transferred more cleanly and safely.
Furthermore, since the substrates are transferred using a plurality of transfer containers, rather than with a stoker and a cassette, the number of transfers required is minimized, and the number of in-process components in the system, and hence, in-process inventory, is reduced.
In addition, a track system that incorporates a linear motor system is one that is easily set up and maintained, and a transfer system using the same can be flexibly embodied in accordance with the needs of the production processing, and production capacity is thus easily expanded.
Moreover, even if specific manufacturing processing equipment is out of order, the other processing equipment is not affected and thus processing flexibility can be ensured.
In addition, since a conventional cassette, stoker, conveyor, and indexer are not used, the initial investment cost of the processing equipment can be significantly reduced, and since the substrates are managed and transferred entirely within the transfer container, the number of in-process components can be significantly reduced at each stage of processing.
By now, those of skill in this art will appreciate that many modifications, substitutions and variations can be made in and to the materials, apparatus, configurations and methods of the substrate transferring system of the present invention without departing from its spirit and scope. In light of this, the scope of the present invention should not be limited to that of the particular embodiments illustrated and described herein, as they are only exemplary in nature, but instead, should be fully commensurate with that of the claims appended hereafter and their functional equivalents.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10-2005-0063233 | Jul 2005 | KR | national |
